PES Wind 4 2021

TALKING POINT into a larger workflow. This could include drone mission preparation, deployment, image sorting, analysis and curation, report generation i.e. PDF, CSV, etc., API integration, and all this with clean user interfaces, amongst other things. Towards the end of 2021 we will publicly release some datasets to support the wind industry to move faster. If you are a solution vendor or a wind operator, feel free to get in touch with us if you want to be part of this open data project at [email protected] www.labelflow.ai Here’s our list of the top players in the commercial missions and is active in over processing. Their solution for automated smart wind turbine inspection ecosystem. 70 countries. We particularly appreciate drone inspections has a particular focus on their simple UI for streamlined image ease of deployment and productivity. Skyspecs was founded in 2016, the capture and analysis. North-American industry veteran has Cornis was founded in 2011, and having inspected over 33,000 turbines worldwide. Scopito leverages their automation and recently joined the SITES group, Cornis Skyspecs combine the power of their machine learning expertise to derive provides a complete set of tools for wind proprietary drone technology, along with all-important insights from your turbine inspections. Their portfolio state-of-the-art Cloud-based asset geospatial data, as well as concatenating includes ground-based camera technology management software to provide a best in historic data to enable powerful predictive with sub-millimeter precision, an class inspection service all over the world. maintenance. Scopito offers a streamlined automated drone inspection solution, as SaaS asset management platform with a well as their Cornis Intrablade solution for Dronebase’s Wind Insights intelligent focus on simplicity, transparency and detailed internal-blade inspections. imaging platform delivers flexible, efficient performance. Their easy onboarding power plant development and inspection process and no-frills approach is a And the list is far from complete, with solutions that provide immediate, welcome addition to the market. other players including DroneDeploy, actionable insights to improve risk Cyberhawk, Aerodyne Measure, Sulzer mitigation and planning. With enterprise SkyVisor is a relatively new player on the & Schmidt. clients worldwide, DroneBase has market, this young and dynamic French successfully conducted over 150,000 team offers AI powered data acquisition 52 PES WIND



TALKING POINT Wave data on board in real time © The TetraSpar Demonstrator Project ApS Radac directional wave radar 54 PES WIND

TALKING POINT Offshore workers know the challenges of finding the right weather windows and suitable sea states. Often it’s a race against time in order to finish the operations within safe conditions. Or worse, you sail out and discover it was all for nothing, due to rough seas and you have to sail back to harbour. Read on to find out how real time forecasting was used during the TetraSpar Demonstrator project. Operations offshore to construct and high structure sailed out with the top part installation side where anchors are preplaced maintain the offshore wind farms are hugely floating and the keel pulled in. As the keel on the sea bed to connect to the structure. affected by the weather conditions. Weather provides stability, the keel needs to be With the keel completely lowered the and waves are the major risk factors for lowered as soon as the water depth allows. At maximum wave height was 2m. offshore operations. Waves especially 6 nautical miles out, at 14m water depth, they contribute to the downtime during projects were able to lower the keel by 4m. The For each step there were wave limitations for as the work is only allowed in limited wave significant wave height for this operation was structure operability and stability. That’s conditions for safety reasons. While wave set at a limit of 0.5m. In other words: where the Radac wave radar comes in. They measurements are often done from completely flat. had to make sure that the forecast was transformer platforms or turbines, it’s also trustworthy and the critical operations could very logical and often more convenient, to Then they had to tow her further out to be take place. Is the actual wave as what was measure waves from a vessel. able to lower the keel completely, 60m and fill forecast? Does it show the same trend as the keel with water. This was done near forecasted? During the whole towing it’s a As Radac is known for her reliable wave Skagen, the most northern part of Denmark. constant flow of checking: forecast says…, radars used in the offshore wind industry, we The limit was 0.8m here. Now the floating wave radar says… and then a go/no go often get questions about our experiences structure is ready to be towed up to the decision follows. Over and over again. on board of vessels. Many construction, pipelaying, and survey vessels have a Radac © Bastian Lykke Bojko wave radar installed to be able to monitor the Radac waveradar (WaveGuide Onboard 2) installed on the towing vessel sea state during their operations. Real time wave data from the offshore wind farm is not always directly available to them. Or the measurement location is too far away from their operation location. The captain of a survey vessel shared with us the following. ‘Very often, forecasted wave data differs from the actual wave data. In such cases, without wave radar we used to wait until the wave trends are confirmed or wait until the light comes up to check it ourselves. Thanks to Radac systems on-board our vessels, we are now able to check, wave-sea state data in real time, regardless the time of the day, and continue our operations which we would have previously missed due to the unknown.’ This is just one example of the feedback we get from the field. To give a more detailed view on the use of wave data at a vessel during operations, in this article we dive into the TetraSpar Demonstrator project (see box). Bastian Lykke Bojko, senior consultant at Blue Power Partners, was on board during the towing campaign and told us all about the project. The TetraSpar project The floating structure of the TetraSpar had to be towed from Grenaa Harbour all the way up to the Marine Energy Test Centre (Metcentre) near Stavanger in Norway, approximately 360 nautical miles. Several critical steps on the route were identified for specific operations. First they took the structure out of Grenaa harbour. Due to the water depth the 166m WWW.PESWIND.COM 55

TALKING POINT ©Bernd Wollesen - Siemens Gamesa Renewable Energy A/S Radac wave radar (WaveGuide 2 Direction Onboard 2) installed on the floating TetraSpar turbine The real time waves were monitored by a Execution of this project required stable check the process as well. During ballasting Radac system that is installed to the railing conditions at sea, therefore the limit of the the ROVs needed to sail around and open the on the side of the towing vessel, close to the significant wave height (Hs) was set to 0.5m valves. The whole process took about one bridge. This motion compensated wave radar for the very first stage of the keel lowering and a half days. is in a single unit system which is easy to event. If forecasted wave data was the only install with a rail mounting frame. The radar source and it was suggesting anything higher And after full keel lowering and ballasting the itself facilitates data acquisition, data than the limited wave height, this could cause wave limit was 2m during sailing. Now the processing, data presentation and remote a significant down time or risking equipment structure is in the final condition of service functionalities as well as internal data and operation. installation, there is the option of the storage. Data will be internally stored on the so-called survival mode of the turbine. She device and distributed over the vessels After this first stage of lowering, second can sit in approximately 13m waves in this network. Any device connected to the stage was set to lower the keel by 60m and mode when anchored. A 4.5m wave height private network of the vessel can access the the acceptable wave height was restricted to was determined as a survival condition, web-based user interface. 0.8m. The operation of keel lowering and meaning they could remain in position with the ballasting itself normally would take a couple tugs and structure, but not make any speed. The unit has to have free sight to the water of hours, but as it is a demonstrator project surface and measures the distance to the all was done at slow pace. The operations are During the last part of the journey they water 10 times per second with centimeter new to everyone and lessons need to be temporarily experienced 3m waves. In this precision. Due to the long term stable zero learned. In this case the ROVs needed to case lowering down the towing speed was reference of the fmcw (frequency modulated consistent wave) radar, calibration is not 250 Hm0 needed. The distances measured are 2021-07-23 compensated for the heaving, pitching and 200 rolling motion of the radar. Thanks to a highly sensitive motion sensor which is 150 incorporated into the radar unit. The Radac WaveGuide Onboard measures the waves Height (cm) 100 the ship actually has to endure. 50 It truly is a plug and play system, which makes it very suitable for these kinds of projects 0 2021-07-13 2021-07-15 2021-07-17 2021-07-19 2021-07-21 where the vessel is hired and comes only a 2021-07-11 Datetime few days before the start of the project. ‘The accuracy always is difficult to say as it can Measured wave data on board. only be held to what I observed. But I’m happy 1st keel lowering 12th July, 2nd keel lowering 14th July to say that it’s very accurate in the way it measures the waves. Leaving the vessel movements out, the net readings so to say, worked very well.’ says Bastian. 56 PES WIND

TALKING POINT ‘In the future, the question won’t be, why your vessel should have a wave radar, but instead, how can you justify not having one?’ enough to encounter the waves. There would During all stages of the campaign, the wave In this case there is an extra advantage as have been the option to sail to shelter as well. data are correlated with the structure another Radac wave radar was pre-installed But this would mean extra risks because of behavior and the towing speeds. And yes, at the TetraSpar floating turbine. The changing the route, crossing maritime you can save the forecast, but that’s a directional system with motion channels and adding extra towing days. Sit forecast. To correlate the data the real time compensation stored all wave data during the and wait in the survival mode was the safer measured waves are of better use. How did campaign and will be very useful for the post option and well within the limits. the waves effect the conditions during processing. Although the real job of this towing and the tension in the towing lines? Radac system, is to monitor the sea state As said before, one of the main functions of And how does the data correlate with the during the life time of the TetraSpar floating the wave radar is to confirm or disagree with engineering aspects like forces on the turbine when she is in function. As there is the forecasts in order to make the go-nogo structure and the tensions on the keel lines? still plenty to learn and discover. Hopefully decisions by the crew. On the other hand, the You can’t do this based on the forecast data. she won’t encounter too many 13m waves. wave data are crucial for the post processing You want to test it from all different angles We’ll have to wait and see! and analyses of the project. to be able to finetune the process and make it ready for multiple installations. www.radac.nl The TetraSpar Demonstrator project The TetraSpar Demonstration Project is the world’s first full-scale demonstration of an industrialized offshore foundation. The project is carried out in a partnership between Shell, RWE, TEPCO Renewable Power, and Stiesdal Offshore Technologies. The TetraSpar foundation is a tetrahedral structure assembled from tubular steel components. It is expected to offer important competitive advantages with its potential for lean manufacturing, lean assembly and installation processes, and low material costs. The foundation and keel were assembled using no welding at the Port of Grenaa in Denmark. A 3.6 MW wind turbine from Siemens Gamesa Renewable Energy was mounted on the foundation at quayside using a landbased crane after the launch of the structure in the harbor basin. In July 2021 the combined structure was towed to the test site at the Marine Energy Test Centre (METCentre), off Karmøy near Stavanger in Norway. Here, the TetraSpar Demonstrator will be commissioned at a water depth of 200m. www.stiesdall.com WWW.PESWIND.COM 57

THINK TANK Leveraging nacelle- mounted lidar for power performance testing As turbines grow in stature, power performance testing and verification become even more important, with underperformance equating to reduced power output and lost revenue. Can nacelle-mounted lidar, with its flexible measurement range, provide a complete testing solution? 58 PES WIND

THINK TANK All around the world, the demand for wind important to derive the strongest Consequently, there will be one standard for energy is growing, both onshore and performance and economic value from wind instruments mounted on a mast, one for offshore. Not only are mature markets farms. To achieve that, Power Performance ground-based lidars, one for nacelle lidars continuing to invest in wind energy, but there Testing (PPT), also known as power curve and another for floating lidar systems. This is also interest in emerging markets. verification, is critical. restructure should allow for easier maintenance of the individual standards. As this industry continues its global With these trends, the limitations of Since environmental conditions during a expansion, an increasing number of projects traditional meteorological masts are more specific measurement campaign can differ are springing up in hard-to-access, remote apparent. Met masts are expensive and from those during calibration, the influence areas. For offshore wind farms, that means challenging to install, and they can no longer of environmental variables (EVs) on the deeper waters further from coastlines, accurately measure up to the full height of measurement accuracy needs to be where wind farms can cover larger areas, modern turbines without mathematical accommodated in uncertainty analyses. erect bigger turbines and generate more extrapolation, which increases uncertainty. According to the soon-to-be-released IEC energy. In onshore environments, wind 61400-50-3 standard, this can be done via a farms are moving to more complex terrain As a result, wind energy organizations are nacelle lidar classification. This classification sites. What’s more, wind turbines are embracing the accuracy, flexibility and involves a two-step approach. constantly growing taller and more powerful cost-efficiency nacelle-mounted lidar The first step is to study the sensitivity of the in attempts to decrease the cost of delivers for PPT campaigns. lidar intermediate values, line of sight producing electricity from wind. measurements, to EVs. The EVs considered Nacelle lidar classification in sensitivity analysis include air The power of power performance testing temperature, pressure, relative humidity, Today, the current power performance density, cloud base height, aerosol density, Combined, these trends make accurately standard (IEC 61400-12) is undergoing a turbulence intensity, linear wind speed assessing wind characteristics much more restructuring process. The main difference variation within the lidar probe volume and challenging. With more expansive areas and with the new structure is that the wind nonlinear wind speed variation within the taller turbines, it is becoming increasingly measurement methods are being treated lidar probe volume. separately from the PPT guideline. The allowed methods for assessing EVs are comparison with reference measurement systems, testing in a lab, and simulations or theoretical analysis. Based on the relationships between these values and lidar intermediate values, we can determine which EVs, if any, are considered significant and taken into account during the uncertainty analyses. The second step is to confirm, using an evidence base, the accuracy of the lidar Wind Field Reconstruction (WFR) algorithm. This evidence base is composed of several campaigns where measurements from measurement instruments, such as met mast, are compared with the nacelle lidar final outputs, such as horizontal wind speed. The evidence base requires at least five campaigns, where the lidar must be installed in an operating turbine in a minimum of two of the campaigns. Robin Cote WWW.PESWIND.COM 59

THINK TANK The off-nacelle tests determine if the WFR were all deployed. The three power curves met tower and ground-based lidar, nacelle- model works and can provide accurate final constructed using the hub height wind mounted lidar is a useful technology to values in a stable environment, while the measurements collected from each support wind project operations and a unique on-nacelle campaigns are the ultimate test instrument were almost identical, and the tool to accurately measure yaw alignment of whether the WFR can provide good final differences in annual energy production and verify nacelle transfer functions. values while tilting, yawing, being blocked by values are negligible, with slightly higher the blades or dealing with any other issue uncertainty using WindCube Nacelle, by Nacelle Lidar installation considerations associated with sitting on top of an about 0.1%. operating turbine. With the increasing usage of nacelle- Even better, correlations between the NTFs mounted lidar for both onshore and offshore Preliminary classification results performed of OEMs against those measured by the power performance testing, there are a by DNV show that the WindCube Nacelle permanent met tower and the WindCube couple of practical points to keep in mind WFR algorithm meets the IEC-50-3 lidar are excellent. Plus, the study revealed when planning a nacelle lidar installation. requirements. The accuracy requirements that nacelle-mounted lidar is often the most Here are key aspects to consider based on GE are fully satisfied for the on-nacelle evidence reliable device to measure yaw alignment. installation guidelines. base, and the off-nacelle evidence base preliminary results show that the criteria are With the study clearly indicating that power First and foremost is safety. It’s vital that the already satisfied within the majority of wind performance testing results using WindCube nacelle lidar stays on the turbine for the speed bins. Nacelle are comparable with those from the intended period of time, so access to an The outcome of the classification is that lidar manufacturer will be able to provide the end-user with: • A list of EVs, if any, that can have a significant impact on lidar intermediate values i.e. line of sight measurements. • An evidence base that proves the accuracy of the WFR algorithm. When performing a measurement campaign, the end-user will assess the difference between environmental conditions obtained during the classification campaign and the specific measurement campaign. In case the conditions observed during both campaigns are similar, no additional classification uncertainty is required in the standard uncertainty calculation method. Otherwise, the uncertainty due to changes in the significant EVs should be taken into account when calculating the final horizontal wind speed uncertainty. Nacelle lidar in action: preliminary findings from a joint study in Oklahoma In anticipation of the release of the IEC-50-3 standard and to support the power performance testing program of ENGIE, a multinational utility company, a joint study between ENGIE North America, GE, Leosphere, a Vaisala company, and DNV was conducted in Oklahoma in the US. As an owner and operator of wind projects, ENGIE aimed to optimize its power performance testing program by evaluating how the different standards, technologies and wind measurement locations could affect the results. With the evolving power purchasing agreement vehicles in the market, nacelle transfer functions (NTFs) become important to accurately calculate the approximate generations, and ENGIE wanted to validate the NTFs used by the wind turbine original equipment manufacturers. For this study, WindCube Nacelle lidar, an IEC-compliant hub height permanent met tower and WindCube ground-based lidar 60 PES WIND

THINK TANK anchor point and a lightning ground is important. The next consideration is loading. Can the nacelle shell handle the extra loading that will be placed on it? There is a wind drag on the nacelle lidar devices, which can introduce higher fatigue and extreme loads that need to be evaluated. Location is also important. Are there any downwind items that could be obstructed by the lidar device? Also, lidar beams need to have a line of sight out into the wind field in front of the turbine, and if there’s no clearance over that nose cone, there will be some impact on the data quality. Another crucial consideration is how the data will be retrieved. In a typical power performance testing campaign, there can be a dedicated data collection system that works via radio and cell modem, but it is also possible to integrate data into turbine SCADA systems, however, that path is much more complex and creates cybersecurity concerns. Access to a power source is another consideration. Be sure to confirm its availability. WindCube Nacelle is installed with a processing unit that takes in the lidar data and computes the wind field, and that processor needs to be mounted in the nacelle with easy access and out of the way. WWW.PESWIND.COM 61

THINK TANK Lastly, are the environmental sensors. Are evidence of the technical suitability and www.vaisala.com/en/wind-lidars/ there dedicated devices on the nacelle lidar industry readiness for PPT using nacelle- wind-energy or do they need to be installed? The answer mounted lidar according to the IEC-61400- depends on your purpose, on the scope and 50-3 standard. www.vaisala.com/en on the target of a campaign. About the author understanding and managing their assets. The key takeaway? Engage early. While every installation is unique based on site-specific Robin Cote is a Product Manager at Hong Liu, Engineering Senior Advisor at conditions and the objectives of the Leosphere, a Vaisala company, where he is ENGIE North America campaign, GE’s standard guidance answers responsible for the nacelle mounted lidars all of the aforementioned installation portfolio and is responsible for building Hong has a PhD in Atmospheric Science consideration questions for most situations. and driving the WindCube Nacelle and has over 20 years’ experience in roadmap. Before joining the wind energy renewables industry supporting project Conclusion industry, he worked in the aerospace development and operations in North industry in several product management America. Hong currently leads the As turbines continue to grow taller, power positions. Robin is currently located in Resource Assessment team and performance testing and verification Saclay, France. manages power performance become increasingly important, as measurements for Grid-scale underperformance equates to reduced Co-Authors Renewables at ENGIE North America. power output and significant lost revenue. Fortunately, nacelle-mounted lidar, such as Luke Simmons, Measurement Service Alex James, Lead Performance Engineer the WindCube Nacelle, with its flexible Line Leader at DNV at GE Renewable Energy measurement range, provides a complete picture of the wind profile, with accuracy and Luke has been focused on power Alex holds a master’s degree in mechanical reliability as good or better than met masts, performance testing of wind turbines for 15 engineering from Cornell University and ultimately enabling wind farm operators to years. As a principal specialist at DNV he is has worked in the wind industry for six maximize power output and profit. also an active member of several IEC years. Five of those years have been with committees including the 61400-50-3 GE Onshore Wind improving performance Overall, this collaborative campaign was an nacelle lidar project team. Luke has led through modeling and measurement. He opportunity for four key industry players to research and innovation projects around has been a user of ground-based lidar data gain high confidence in performing power the application of nacelle lidar, including in for performance measurement performance testing using WindCube Nacelle complex terrain, since 2013. Currently he is throughout that time and more recently and ensure a cost-effective and working on a variety of lidar measurement taking on additional responsibility for straightforward approach throughout applications to provide the industry with nacelle lidar turbine integration for the GE installation, data collections and data analysis. the highest quality results for Megawatt Constrained fleet. The joint campaign also brought compelling 62 PES WIND



PES ESSENTIAL The race towards neutrality 64 PES WIND

PES ESSENTIAL As the move towards carbon neutrality gathers pace, offshore wind farms will offer increasing opportunities for employment and prosperity. PES looks at how hubs such as Denmark’s Port Esbjerg can play a pivotal role in the sector. The green transition is making headway, and in integral part, to find out how the future less than a decade many countries are opting workforce within the offshore renewable for steep reductions in carbon emission. It is a industry can be developed. situation that creates a buzz in many industries that will be affected by the change in society The need is related to Port Esbjerg’s position currently dictated by the environment. as one of the epicenters for offshore wind in Europe. But the task force is also meant to Changing the energy mix is the initial step, contribute to meeting the high standards of where the wind industry represents 40 years Denmark’s ambitious Climate Act. onshore, while offshore has risen steadily over the past 20 years. The near future will The Danish Climate Act stipulates the see the same industry also allowing for requirement for a 70% reduction in carbon greener fuels to be delivered to trucks, emission by 2030. This entails the trains, and ships, transporting greener construction of an energy island surrounded products around the world. by 10 Gigawatts of offshore wind. The potential for a surge in jobs is evident, and Ports are vital in these networks and will the creation of education specific to the therefore also play an instrumental role in industry is a necessity. the transition of the logistics networks. They are needed for installing offshore wind The task force was a collaboration between farms, for handling electrical fuels and for the 80 companies working in the offshore supplying ships with various types of fuels. wind industry in Esbjerg and it began by The green transition will entail new business trying to find out how education of multi- areas, job creation and prosperity for many skilled specialists is created. societies, and the question remains, how to reap the benefits? The task force, together with vocational schools, training centers and the The big job creator is offshore wind municipality, as well as the companies in the supply chain, created ‘Green Skills’. In 2020, the socio-economic impact study of offshore wind was released which indicated This approach moved beyond the need of a the possibilities for job creation. In essence, specific company and allowed for co- the report revealed that for every gigawatt of development, where companies share a pool offshore wind installed, more than 9,500 of trainees to develop the specialist full-time job equivalents are created. education required for offshore wind and thus Denmark’s green transition. The potential for 300 gigawatts of offshore wind in Europe therefore triggers an This guarantee of being able to source a abundance of possibilities, while raising the competitive workforce allows companies to question of how to find the workers and develop strategies of growth in conformity to determine how they should be trained. the plans for offshore wind in Europe. The production of wind turbines does, of Investing for the surge in offshore wind course, require the most workers, but as activities are conducted offshore, crews for At Port Esbjerg, the strategy of the supply vessels and operators for ploughing, chain for offshore wind provides the trenching, jetting and cable laying, in addition assurance that these activities will be relevant to technicians for the wind turbines, all need in the future. The intentions of the supply to be trained specifically for the tasks they chain to grow with the offshore wind industry are to perform. also allow Port Esbjerg to invest accordingly. The forecast scarcity of these specialists This was manifested through the could well be another bottle neck in commencement of a further 570,000 square installing the wind farms, with the pace meter of port expansion, in addition to the dictated by the plans for offshore wind in development of bespoke pre-assembly sites Europe. The question remains how these available for project lease. specialists are trained. The situation portrays a tripartite Training to meet the needs of the supply chain relationship between ensuring competency, investing for growth and ensuring port In Esbjerg, Denmark, the city council created infrastructure to participate in the a task force, of which Port Esbjerg played an installation of future offshore wind farms. WWW.PESWIND.COM 65

PES ESSENTIAL The focus on ports in growth scenarios is not companies not directly linked with the the key contributors were the experienced new. In 2013, the European Commission erection of wind turbines. Norwegian ship designer Naval Dynamics and launched the communication on ports as Hagland Shipbrokers, which focuses on the engines of growth, where the need to Creating new innovative business models offshore wind segment. modernize ports, while at the same time respecting the environment, was discussed The offshore wind industry is the forerunner The idea was to design a crew transfer vessel in context to servicing the hinterland and in the green transition, but there is also the that was competitive in current market catchment areas. same possibility within the maritime conditions while being future-proof and industry, as more than 200 new vessels will available for sale or lease for maintenance In offshore wind the picture is mirrored and it be needed over the next decade. contracts that ensures the uptime of is the ability to perform the installation of the operations. future wind farms that will dictate the speed Owners of wind farms should be able to of the green transition. perform maintenance, with multi skilled The hull design of the crew transfer vessel specialists being transported on zero- minimizes water resistance and hence the In May 2021, WindEurope stated in their emission crew transfer vessels. This will power needed to achieve service speed, report considering the 2030 vision that ‘To require vessels that are bespoke to the while a range of machinery is available, deliver the offshore wind expansion set out in location of the wind farm, which in return will including eFuels. the EU’s Offshore Renewable Energy be met with the demand for long-term Strategy, Europe’s ports must expand and contracts from the owners investing in these The creation of this future crew transfer add new infrastructure’. vessels. However, such long contracts may vessel shows how belief in the future pause the innovation needed to deliver possibilities of offshore wind can drive the Conversely, the attractiveness towards the zero-emission crew transfer vessels. decision of companies to participate. This is offshore wind industry is a duality between obviously driven by the need to prosper, but the companies operating within the port and Esbjerg Shipyard, being part of the Granly in many cases the companies also aim to play the port authority, and any collaboration that Group, set out to develop a crew change an active role in the green transition. may increase efficiency or reduce cost allows vessel, which is efficient today but can also for leadership in the competitive landscape. be converted to future fuels to allow for The combination of participation due to zero-emission transfer of technicians from personal or company gain, coupled with the This phenomenon ensures that the supply shore to wind turbines. requirements of society and the will to make chain in Esbjerg, together with the Port, is an effort with regard to the climate are what ready to engage in even more offshore The idea generation was carried out in generate new innovative business models. wind projects in the future, but it does also co-operation with an abundance of This is, however, not possible without the yield new innovative possibilities for stakeholders, hereunder Port Esbjerg, but involvement of multiple stakeholders, and 66 PES WIND

PES ESSENTIAL ‘The offshore wind industry is the forerunner in the green transition, but there is also the same possibility within the maritime industry, as more than 200 new vessels will be needed over the next decade.’ their combined action will create the As offshore wind ports today have become adequate and correct port infrastructure for structure for prosperity in the race towards spatial clusters, which include part of the the installation and maintenance of the carbon neutrality. supply chain, they have also become future offshore wind farms. hotbeds of innovation. This is achieved The creation of the structure for prosperity through strategic partnerships between The green transition requires port companies operating within the port, authorities to revisit their role and engage The recipe for prosperity in the green coupled with pioneering entities monitoring with the plethora of possibilities within the transition entails competencies, capabilities, the port ecosystem. offshore wind industry and thereby create and competitiveness, built on the foundation the desired socio-economic effect by of people who are able to collaborate in new Port Esbjerg is co-creator and a participant in participating in the green transition. ways. And they must do this both to the many different projects, and this naturally benefit of the individual, the community, and supports the main objective of delivering www.portesbjerg.dk the environment. WWW.PESWIND.COM 67

ASK THE EXPERTS Wind farm management in a digital world Carlos Blanco, Sales & Marketing Director at Sparksis, explains to PES how digital technology is speeding up the inspection process for wind farm owners, with data collection methods that are already proving popular in France now making their way to the UK too. 68 PES WIND

ASK THE EXPERTS Carlos Blanco PES: It’s great to welcome you for the first Secondly, Ingrid control is a substation PES: What are some of the main time to PES Carlos. As a relative newcomer monitoring and control solution which advantages that you feel Sparksis brings to the industry and certainly to the UK enables better integration of wind farms to to the industry and what are its unique market in particular, it would be good to the grid and the market. Companies such as selling points that make it different to begin by introducing Sparksis to our BayWa, Vestas France, ERG, Ostwind, what’s already available? readers if you will? Eurowatt are using Sparksis’ products in their daily operations. CB: Our solutions have been designed by an Carlos Blanco: Sparksis is a French start-up IPP for IPPs. The Eofix users particularly that designs, develops, and markets PES: The business is now turning its appreciate the user-friendly mobile innovative solutions for the operation of attention to wind farm owners in the UK; application to conduct wind turbine and wind farms. Two business-oriented how big a market do you see this being substation inspections. The tool has been solutions, initially developed by an for you? initially designed for wind farms compared to operator, currently make up Sparksis’ other multi-sector solutions existing in the product portfolio. CB: We believe our solutions may be of market. Therefore, its database structure interest to small to medium size IPP/operators and workflow are really oriented for wind Firstly, the Eofix mobile application allows of wind farms, as is the case in France. We have farms installations. We are also publishing on-site visual inspections using easy-to-use a step-by-step approach. We are conducting a updates regularly based on user feedback. customized checklists. All the data collected market entry in the UK with the help of with the mobile app is monitored and Business France to test the appeal of Eofix Finally, we offer one unique full functionality managed through the web application. The within the UK market. If the feedback is version and our pricing is based on a evolution of the non-conformities is tracked positive we will invest more effort. pay-per-use model. We hope UK operators until their resolution. will appreciated Eofix as French users do. PES: How big a problem is it, do you think, that much of the wind farm industry still relies on quite traditional forms of reporting inspection results? CB: The problem for an operator to use the traditional way to do visual inspections using an excel file checklist and taking photos with a mobile phone are many: time wasting, poor quality of the data collected and reporting, difficulty to use the data to follow up KPI’s and more. PES: What are the main challenges and drawbacks of this? It must be quite time consuming and costly to do it this way? CB: Yes, it is. One example to illustrate it is the edition of an inspection report, which is time consuming. On site operators don’t need to spend hours at the office to create reports. They’d be better off on site to look after the proper functioning of the installations. PES: So how can digital technology, such as Eofix, help change this? CB: The answer is easy and not very original. WWW.PESWIND.COM 69

ASK THE EXPERTS Eofix allows inspectors to fill-in customized checklists on site and to monitor every open non-conformity to be solved It is the common use case for digital operators can give a specific user access to its over the remaining non-conformities. solutions. Basically, the use of an Eofix service providers so they can connect to Eofix mobile application to conduct inspections via mobile and web and solve the non- For Eurowatt, French IPP, the adoption of and update existing non-conformities tickets conformities for which they have been defined the tool eliminated the tedious task of on site and the web application to centralize as the resolution manager. There is no need writing inspection reports. They have and share all the data. any more to update and exchange files by estimated this reduction at 0.2 man-days email. Our clients needed to convince the per wind turbine per year, so that is to say 20 PES: How easy is it to digitize the inspection service providers as the turbine man-days per year for 100 Turbines. This process? Can you briefly explain how the manufacturers in the beginning to use the represents approximately €12,000 per year Eofix tool can be used? tool. But now, they realize Eofix is a very useful in time savings. tool and it makes life easier for them as well. CB: The user administrator creates as many We are glad to say that every Eofix user customized checklists as needed on the web PES: What are the benefits of using such would not imagine coming back to the application and gives access to them to the technology in terms of establishing trends notepad and pencil. authorized operators on their mobile in non-conformities and the general application. The inspectors will have the ongoing management of maintenance PES: Thank you for sharing that insight with checklists on their mobile and will fill in all the of turbines? us, I’m sure our readers will find it helpful to data requested for each checkpoint, such as get a feel for how the technology is already description, severity, photos, resolution CB: Having all the data available on Eofix being used. Just one or two final points manager, due date, etc. All the data will be Datawarehouse makes it possible for before we close; how important is it, do you synchronized in the cloud and the report can operators to create their own KPIs using think, to improve the quality of data and be immediately created and shared from the business intelligence tools. This is good for reports in this way, particularly as the web application. following up trends, comparing service industry evolves and gets even bigger? providers performance to solve the PES: For wind farm operators and non-conformities, managing periodic CB: I think everyone is now convinced of the managers looking to go down this route, do meetings, and ensuring the installations are importance and value of data management. they need to invest in any particular in good condition and working at their Eofix makes it possible to digitize a technology or equipment to carry out maximum performance. traditional process and therefore exploit the on-site inspections digitally? inspection data. PES: It sounds fascinating and a great way CB: No. A recent mobile terminal and a PC are forward for wind farm inspections. Do you PES: Do you think this is just the beginning the only equipment needed. have any real-world examples of Eofix being and that there is even more potential for used that you can share with us? digital technology to inform wind farm PES: How secure are the results and is it management in the future? straightforward to then share them and CB: We have many case studies we can talk resolve issues? Presumably this is a far about. For example, Vestas France uses Eofix CB: Yes, at our level we are working on quicker process than with notepad and to define the ‘Punch list’ at the end of their database interoperability and AI, to make pencil in the traditional way? wind turbine installation and solving Eofix reach a next step on the inspections non-conformities quicker, and transferring digitalization. CB: For sure. One benefit of Eofix is that them to the O&M department who will take www.sparksis.eu/ 70 PES WIND

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CORPORATE FOCUS Transforming the market for bushing design Xavier Pinol, Sales Manager EMEA & Asia and Sebastian Miranda, Sales Manager Europe at The H-J Family of Companies, discuss the importance of customizing bushing designs for wind turbine MV transformer applications. As technology evolves and MV transformers and thicknesses can be adjusted. The size, connection needs, as well as the spade are located in the turbine nacelle next to the shape, and number of holes could be orientation, which could be rotated or even generator, it is more important than ever to adapted to the transformer’s internal be offset. have the appropriate transformer bushings. Internal connection from winding to bushings, example for 7500A LV Bushing Series Higher ambient temperatures, higher transformer insulating temperatures, frequent vibrations, smaller spaces, and costly possible repairs translate into the critical choice of the right bushing design. Fortunately, epoxy resin bushings can be adapted to match each application. The combined efforts of the turbine manufacturer, transformer manufacturer and bushing manufacturer can result in a successful design. To verify new bushing designs efficiently, it is imperative to have an in-house high voltage test lab capable of handling the numerous tests needed, initially for R&D and later for production. Here is an overview of potential bushing customizations: Internal connection from winding to bushing Smaller size in transformer designs with a higher power has created requirements for custom internal terminations, allowing transformer manufacturers to optimize their designs. Typical terminations can include milled flats, spades, or threaded studs. Dimensions such as length, width WWW.PESWIND.COM 73

CORPORATE FOCUS External connection from generator to bushing Turbine manufacturers face several challenges when optimizing the space within the nacelle and defining the optimum connection mechanism with the transformer, such as flexible connectors, fixed copper bars, quick connection boxes, among others. External terminations are easily customized to the application in order to fulfill the space and connection requirements. External connection from generator to bushings, example for 7500A LV Bushing Series Customized examples for 7500A LV Bushing Series Compact dimensions of epoxy body and terminals In addition to the terminals, the bodies and structure of the epoxy resin bushings are much more compact compared to other insulation options. The casting process allows for maximum creativity in bushing design for all applications. Comparison between porcelain bushing and epoxy bushing. Same ratings 1.2kV, 2000A, 30kV BIL 74 PES WIND

CORPORATE FOCUS Easy offering of appropriate current rating An extensive portfolio of bushing bodies and conductor configurations are available for a wide range of voltage classes and current ratings. Electrical ratings are adjusted to each customer’s particular needs rather than customers adjusting to a fixed portfolio. Low voltage bushing designs range from 30 amps to 10,000 amps and voltages of 1.2kV, 2.5kV, 3.6kV and 5 kV. Extensive portfolio of bushing bodies and conductors to offer designs for currents up to 10.000A Tin, nickel and silver plating available solution would be nickel plating, which not Epoxy resin formulations available for only provides a good corrosion resistance indoor and outdoor exposure. The standard solution provided for the but also wear resistance. Finally, bushing copper bushing terminations is a coating of terminations can be silver plated, which Our proprietary epoxy materials are tin plating. It provides a good protection layer enhances electrical conductivity while still designed and formulated in-house for both against corrosion, while featuring a better providing corrosion resistance. indoor and outdoor applications. contact surface. Another available coating Plating options for epoxy resin bushings Epoxy formulations for indoor and outdoor exposure Ability to provide designs for 105C, 120C and 155C insulating systems Epoxy formulations for different temperatures, including one material suitable for high-temperature applications up to 155°C. Ideal for transformers installed in the nacelle, where the ambient temperature tends to be high. Epoxy formulations for different operating temperatures WWW.PESWIND.COM 75

CORPORATE FOCUS Sealing options according to transformer and application needs Sealing Options Installation clamp options To fulfill different transformer sealing designs, bushings are available with options for flat gasket surfaces, gasket retaining grooves or flat gasket surfaces suitable for use with a machined tank surface with O-ring seals. Based on the design of the bushing and the application, the fixing clamp is adjusted or developed Compatible with various insulating fluids like mineral oil, natural esters and synthetic esters Epoxy bushings are compatible with the range of fluids used in current renewable applications. www.h-j.com Epoxy bushings compatibility 76 PES WIND

articulo revista h-j-Final.pdf 1 30/10/21 6:17 a. m.

ASK THE EXPERTS Making light work of container accommodation PES caught up with Hans Gatzemeier, CEO of ELA Container Offshore, Germany, to find out what is being done to cater for the need for nearshore accommodation in a flexible, cost-saving way. PES: Hello Hans, I am very pleased to be customers’ demands. We can now look development of this product? talking to you again for the last edition of forward to full order books for the next few PES Wind in 2021. With the year now years. They involve interesting European and HG: We have gradually built up and expanded drawing to a close, how have you found it worldwide projects in the field of renewables our business by renting and selling offshore in terms of the developments in the and show us which markets we should pay containers and their accessories. Our rental offshore industry? more attention to. fleet now comprises more than 750 units, which are available for short-term use. The Hans Gatzemeier: We have achieved the PES: On the subject of developments, when advantage of this is that the customer only goals we set ourselves and are therefore very we last spoke you mentioned that ELA has uses and pays for the solution when there is pleased with how the year has gone. During developed Offshore Light as a new an exact need for it, which is what makes this the pandemic, we did our best to meet our container type. What prompted the such a popular option in a market where 78 PES WIND

ASK THE EXPERTS flexibility is so very important. Its empty weight is about four tonnes, containers particularly suitable for? depending on its equipment. This makes it However, we were often asked whether we ideal for use on pontoons that have been HG: We expect them to be used in coastal could also provide containers for the moored alongside quays or for use on barges and inland waters. However, they are also nearshore sector, or even for use in ports. We operating in inland waters or in harbours. ideally suited to the onshore sector, perhaps could, of course, use our offshore containers, for use in harbours and coastal areas where but they are somewhat overqualified for this PES: Who are your Offshore Light harsh weather conditions prevail, and a solid job. We have therefore developed a product and weatherproof solution is required. They that is specifically designed to meet these have a high insulation value, which makes it requirements. The key, as always, is to comfortable to work or sleep in them. provide a flexible solution to meet the needs of the individual client. Time-saving, Of course, the containers are designed to the space-saving and cost-saving are all health and safety standards for the offshore important too. wind industry, as well as to meet the comfort needs of those using them. PES: That sounds very logical. Can you explain how the Offshore Light container And in an industry where reducing costs and differs from the other offshore containers adhering to tight budgets and strict timelines in your product range? is so important, the Light Containers are a suitable all-round solution. HG: Our 20ft ELA Offshore containers are exclusively for offshore use and are built from PES: What advantages does this new scratch in our factory in Haren. Their solid product offer your customers? structures and their pad eyes allow them to be certified in accordance with ISO10855 / HG: With the Offshore Light container, ELA DNV 2.7-1 / EN 12079-1 and the CSC. They has another container type in its product can therefore be lifted and loaded offshore. range that can be used in diverse ways They are equipped with A60 insulation in depending on the customer’s purpose. The their walls and ceilings to meet further pricing model is attractive, reflecting our offshore requirements. With their solid savings in materials. structure and compact insulation, they have an empty weight of 7.7 tonnes. Customers can rent or purchase this new product and can combine it freely with our Our new product, the 20ft ELA Offshore offshore containers and accessories. Light container, is a modified transport container. After modification, it receives a PES: This has made your product range even new CSC certificate and is equipped with more varied than it was. Does it come with thermal insulation and B15-certified wall as many different choices of equipment as and ceiling panels. your other containers? If so, what equipment comes as standard? HG: All choices of equipment are of course available, as with our standard Offshore WWW.PESWIND.COM 79

ASK THE EXPERTS a sanitary unit inside and air-conditioning unit integrated in a space-saving way and container. It can therefore be used for living centrally accessible. quarters, offices, meeting and changing rooms, kitchens and even fitness rooms. We This is important because the nature of the also offer double rooms. These have a floor industry dictates that such accommodation space of about 30 square metres and are is often required at short notice, and this ideal for meeting or recreation rooms. makes it quick to respond and cater to PES: Can you also build and equip the changing requirements. Offshore Light container in accordance with the customer’s individual requirements? PES: Before we conclude, it would be HG: Yes, of course. We have recently interesting to hear what your goals are completed a two-storey unit in accordance for 2022? with a customer’s requirements. These included extra windows with blinds, a side HG: Our goals for 2022 are to continue to door and smaller toilet windows. improve our know-how and to offer our In principle, anything is possible. We are customers added value, not only with our flexible and follow the customer’s standard products but also with special requirements to the letter with respect to containers in all sizes and dimensions. Our the interior. containers are extremely versatile, and I PES: You can use accessories, such as think people will hear a lot about ELA during gangways and stairs, to assemble the the next few years. containers as complex systems. Is this also possible with the Offshore Light www.ela-offshore.com container and are the accessories from your product range compatible with this new container type? HG: We can, if necessary, quickly and easily combine this container type with any of our others. This also applies to our accessories, including gangways, stairways and stairway containers. Our containers can be stacked four high and are declared as CSC containers when customers transport them by ship. This makes it much more attractive to transport them worldwide. Our customers can assemble the containers themselves on site, because we have pre-installed our ELA Plug & Play system in them. This means they can be immediately ready for use, with all the necessary power connections, water pipes if the container has 80 PES WIND

Digitalize your inspections and O&M data Eofix is a digital solution dedicated to wind farm inspection data management. Use a single tool to perform inspections, centralise data from different sources, track non-conformities until resolution, analyse data and generate reports. www.sparksis.eu Innovative solutions for renewable energy operators

THINK TANK Smart SCADA and the use of digital twins in renewable energy plants Words: Jorge Acedo, R&D Control Systems Director of Ingeteam Wind Energy As the installation of renewable energy projects continues to grow worldwide, so too does the need for smart SCADA tools to manage their day-to-day operations and optimize performance. SCADA solutions are responsible for ensuring this is performed to meet the needs of all key stakeholders. SCADA solutions intended for renewable energy control centers need to have a comprehensive approach, adopting best-in-class digital tools to create a complete suite, accompanying the data from real- time acquisition to supporting O&M and strategic management decisions. Successful integration of state-of-the-art solutions into one single product is key to solving the most complex operational challenges. Each renewable energy project has its own The key goal of digital twins and advanced Jorge Acedo unique characteristics linked to the analytics is the use of data to gain environmental features and topography of important insights into the health and their specific location. No two projects are performance of renewable assets to identical, each asset owner faces different support the decision-making processes for challenges, depending on the mix of assets the operation and maintenance of those and systems it has. That is why there is no assets throughout their useful life. one-size-fits-all solution, and Understanding the performance, customization is a key success factor when identifying underperformance, and taking deploying such a system. corrective maintenance actions can deliver true value creation and extend the lifetime One of the most important tools to be of the assets. integrated in SCADA solutions for renewable energies are digital twins. These advanced The following case study is focused on analytical models are increasingly used to data-driven digital twin based on real-time solve problems arising from the management SCADA data using Ingeteam’s INGESYS™ of renewable assets such as wind farms and Smart SCADA product. Asset owners can photovoltaic plants to improve performance easily analyze this SCADA data using the and extend their useful life. company’s analytics tool suite. 82 PES WIND

THINK TANK Analytics Tools of INGESYS™ Smart SCADA Deploying a data-driven digital twin to All the data available was integrated into the INGESYS™ Smart SCADA analytics monitor multi-technology asset portfolios INGESYS™ Smart SCADA to build the Digital modules. These models learn the normal Twin of its fleet, through the creation of behavior of the components and The use of data-driven digital twins and data-driven models for the assets. This was continuously track performance, raising advanced analytics to support the decision- performed by: alerts to any deviations from their normal making processes on the operation and patterns. These alerts allow the management of renewable energy assets • D etecting key component behavior technicians to focus their resources onto throughout their useful life provides changes and trends. The operational the right units. multiple benefits. Ingeteam’s INGESYS™ performance of each plant in the portfolio Smart SCADA product, integrates these is monitored using Key Performance • Applying visual analytics. Time is a scarce functions within its Renewable Energy Indicators (KPIs) providing an overview of resource for field technicians. Visual Control Center solutions. the health and performance of each unit. analytic tools (see examples above) allow KPIs are automatically created and can be technicians to easily explore the huge An asset owner in Latin America, with a easily used across the asset owner amount of data generated by the assets portfolio spanning 4 countries, including organization to measure and direct the and identify performance issues without wind farms and photovoltaics plants, needed O&M efforts. needing the skills of data scientists. to unify the data generated by its wind and solar assets to create value. The real • I ntegrating machine learning algorithms • Analysis of performance and power challenge was to build a central SCADA to detect anomalies. Machine learning curves. Asset performance is a key factor platform to so that it could optimize its O&M models for each key component in the that must be closely watched. Machine strategy decision across different wind farms and solar plants are created learning models and KPIs detect early technologies and countries. and deployed within the INGESYSTM deviations from the underlying trends. WWW.PESWIND.COM 83

THINK TANK ‘As a result, in the first year following the implementation of improvements, the client generated estimated savings of over $500,000.’ Dashboard Machine Learning Models Routine reports can be generated Applied data science not only provides and O&M technicians to performance and automatically, freeing up time for client performance improvements. Security reliability analysts and managers, to have the technicians to focus on O&M tasks and apply enhancements for aging assets is also a key right tools and the necessary information to the insights gained through data analytics. value driver in asset management. For meet their specific needs within one central This is achieved by means of easily instance, the client was able to spot platform. Information is available for each customizable dashboards. abnormal thermal behavior in a subset of the user type without division into difficult to transformers. This insight allowed the client access silos. Within our Smart SCADA Below are three examples of issues identified to launch an O&M campaign to correct the platform, a suite of specific tools can be thanks to the digital twin and data analysis: issue before it escalated further. optimized for each specific stakeholder. Moreover, the overall decision-making Identifying underperformance Curtailment losses process was improved across the full organization, beginning with real-time Using the digital twin created for the specific In another example, the curtailment losses operators, field technicians and ending with assets of the client, a comprehensive associated to a specific solar plant were skilled O&M analysts and managers. performance analysis was carried out. This calculated in fine detail and economic savings analysis detected that one of the wind farms in were achieved by means of joints work with In the case study presented, we focused on the portfolio was not performing as expected. the transmission system operator (TSO). the data-driven predictive tools inside our INGESYS™ Smart SCADA platform. We Together with the client, the root causes of this Conclusion have demonstrated how one customer with underperformance were analyzed and a portfolio of wind and solar assets in identified, and corrective actions implemented Overall, the deployment of the Central several Latin American countries has at the affected wind farm. This is just one SCADA improved the internal processes achieved significant cost savings and example of how the insights gained through and decision making for managing all the improvements both in asset performance data analytics can be applied to correct specific client’s assets. As a result, in the first year and security. Therefore, we can conclude problems. When the client detected a problem, following the implementation of that INGESYS™ Smart SCADA was a key they were able to concentrate their O&M improvements, the client generated factor in the digital transformation of our efforts only on the affected wind turbines. estimated savings of over $500,000. customer asset management. Enhancing security The use of digital twins and advanced www.ingeteam.com analytics enables all users, from operators 84 PES WIND

WHAT CAN NATURE TEACH US ABOUT OPTIMIZING WIND ENERGY PRODUCTION? A murmuration, or flock of starlings, results from the graceful balance between group cohesion and individual effort. Inspired by nature, WindESCo takes a system approach to wind plant optimization. Through years of data analysis, modeling and testing, we've developed cooperative control technology that delivers 3-5% AEP gains site-wide. WindESCo Swarm™ uses collaborative interaction between turbines to maximize an entire farm's output potential, rather than optimizing turbine by turbine. Find out more at windesco.com/swarm

THINK TANK Optimizing wind plant production with cooperative control 86 PES WIND

THINK TANK WindESCo discusses why taking a collective approach to energy production improvement, by thinking of a field of wind turbines as a system rather than viewing single turbines in isolation, could have a positive impact on performance levels. Underperformance is a key challenge in the wind industry, garnering the attention of investors, independent power producers, utilities and corporate buyers alike. Despite a growing market of dashboarding solutions that attempt to identify underperformance, little progress has been made at recovering the AEP that is so often lost at wind farms compared to projections. Original equipment manufacturers have also grappled with the underperformance of their turbines, but commercial solutions designed to improve energy production fall short. For years, WindESCo has consistently driven 1 to 2% AEP improvement at wind plants, using high resolution data to uncover and fix wind turbine under-performance. With the launch of its next-gen solution, WindESCo Swarm, a way to realize 3 to 5% improvement across a site. Taking a system approach The world we live in is digitally and socially interconnected. Businesses, individuals and nations increasingly understand the value of cooperation. Despite this, wind turbines, even those in large plants, almost exclusively operate independently. Turbine operators employ control strategies designed to maximize individual asset production, rather than working together as a collective, cooperative unit to achieve wind plant optimization. This isolated operational approach amplifies reactive and local turbine control behaviour, that is the behaviour that results in turbines constantly chasing the local wind effects. It also generates turbine-to-turbine wake effects that hinder wind plant optimization. Individual assets are optimized, while the overall performance of the plant suffers. As a result of these turbine-centric control strategies, wind plants regularly lose WWW.PESWIND.COM 87

THINK TANK between 5 to 20% of their potential power1. decision-making of birds in flight, WindESCo models. The system can also be made part of Swarm™ enables turbines to cooperatively new wind plants or as a retrofit solution offered A lot of research has been done or is ongoing adjust positioning to boost production for by OEMs and controller manufacturers. to manage the wake effect by steering or the entire farm, not just single machines, by derating the upstream turbines. However, 3-5% annually. By swarming a wind site, The retrofit Swarm application can be divided few have generated sufficient AEP WindESCo has introduced an autonomous, into four layers: improvements that could justify the cooperative control technique for additional hardware and software costs continuously optimizing AEP. Swarm Edge: the IIoT edge device and required for wake mitigation. software connected to the turbine controller The Swarm technology stack get real-time turbine level data and Introducing swarming implement cooperative control. By combining hardware and software as an In nature, many species have realized the integrated system, owners can unlock value Swarm Server: the wind plant level server evolutionary benefits of operating as a by allowing turbines to communicate with within the firewall that communicates with coordinated unit. Beehives, starling flocks and and learn from each other. To develop the each Swarm Edge and the wind plant herring schools, for different reasons, group system, WindESCo used a multidisciplinary SCADA server. together in large numbers and move in sync. approach, combining the fields of turbine loads, controls, meteorology, sensing and Swarm Software: the core software layer In the same way, WindESCo developed a new machine learning. running on the Swarm Server that technique to swarm wind turbines, allowing communicates with all the Swarm Edge devices them to become social, reacting to their The system has been developed with three and makes real time optimization decisions. neighbours, and sharing information to years of concentrated effort and has been continuously optimize AEP for the entire plant. tested on 13 turbines on two wind plants. The Swarm Cloud: the offline data analytics and first commercial implementation on three wind model optimization layer that provides Taking cues from nature, and the intuitive plants with over 300 MW of capacity is longer term analytics and visualization of 1 L ee J. C. Y. and Fields J. M. “An overview of wind- underway in North America. It is currently Swarm effectiveness at a wind plant. being offered as a retrofit solution that is energy-production prediction bias, losses, and compatible with most turbine OEMs and Offering multiple value propositions, when uncertainties.” Wind Energ. Sci., 6, 311-365, 2021 combined together, can increase Annual https://doi.org/10.5194/wes-6-311-2021 Site A Site B Energy Production between 3 to 5% at a wind plant level. Below are some examples of the Capacity 80 MW 248 MW different applications that have been 0.5 % 1.1 % implemented as part of the Swarm system. Estimated Annual Benefits $107,000 $300,000 88% 74% Yaw by consensus Reduction in Yaw Actions 83% 88% When each turbine operates independently, Reduction in Yaw Distance Traveled it must solely rely on its sensors to determine the wind direction and appropriately modify its control settings. These sensors are typically mounted on the nacelle and measure the flow direction at a signal point near the center of the rotor, which doesn’t 88 PES WIND

THINK TANK adequately characterize the average flow predicted wind direction from nearby profit generation for project owners. through the wind turbine rotor sweep. turbines to help capture more energy or reduce extreme loading on the turbines. The table below shows an example financial By combining measurements from varying model with a five-year Net Present Value and subsets of turbines in the wind plant, a Monitoring and updates over Return of Investment for the System-as-a- comprehensive characterization of the wind secured network service model mentioned above. plant complex flow field can be determined and the yaw positioning of individual turbines Swarm is not a static upgrade for your wind Asset longevity case study can be optimized to maximize energy capture. plant. Instead, it will get even better over time, through remote monitoring and As part of Swarm’s development, WindESCo In this way, by sharing knowledge of the wind offline data analytics. WindESCo is has deployed software and hardware on test all turbines can improve their performance. continuously improving the system, site wind farms in the US. This prototype This is known as yaw by consensus. applying the latest state of the art analytics testing demonstrated the ability to perform and algorithms to achieve even better energy performance optimization with no This increases energy capture while minimizing performance on wind plants. adverse effects on asset lifespan. total yaw activity. The following benefits were estimated for two recently analyzed plants. Significant returns on investment In addition to measuring changes in power performance, these turbines are instrumented Wake steering Two financial models were considered for for blade root bending load measurements and swarming. The first financial option is through the damage equivalent loads are measured Wind plants lose between 5 and 20% of their WindESCo’s System-as-a-service (SysaaS) with and without wake steering. output to wakes. One of the most effective model, similar to common software-as-a- strategies for mitigating wakes to increase service implementations. This model delivers Analysis showed an anticipated change of less the overall plant production is wake steering. hardware, software and implementation to a than 1% in fatigue loading on these turbines Here, the yaw position of the upwind turbine customer for a recurring service fee. and experimental results for the period is modified so that it no longer faces directly analyzed support this result by showing no into the wind. The second takes advantage of significant tax statistically significant difference in the fatigue benefits available in the US market through loading on the turbines when wake steering. As a result, the downstream propagation of the Production Tax Credit (PTC) program for the wind turbine wake can be deflected, or repowering equipment. Similar tax incentive Conclusion steered, away from the downstream programs may exist in other markets. turbines. The downstream turbines are then Optimizing turbines in a one-off manner has exposed to undisturbed higher velocity flow The Return of Investment and the Net not generated significant enough AEP gains and can generate more energy. Present Value for customers, showing that to move the needle on the value and continuous optimization through WindESCo profitability of wind assets. Meanwhile wind Although the upwind turbine will produce Swarm over consecutive years unlocks plants consistently miss production slightly less power than if it were pointing cumulative AEP improvements and increased expectations by 8 to 20%. directly into the wind, the wind plant as a whole will generate additional power as a 2.5 MW 1.5 MW To solve this problem, the industry must move result of the wake losses being mitigated. away from its single-turbine approach to AEP $15.8 - 30.1 Million $14.0 - 28.4 Million improvement and instead think of a field of Other Swarm applications wind turbines as a system, which must work Up to 5.3 times Up to 3.8 times cooperatively to perform at its peak. This can Two additional applications are introduced by now be achieved through swarming. WindESCo Swarm that provide further Less than 1 year automated benefits to a wind plant through WindESCo Swarm is commercially available yaw control improvements. OEMs have and licensable technology that allows wind optimized their yaw controllers for a specific plant operators to capture 3 to 5% additional set of general site conditions, however, AEP without reducing asset longevity. decisions about when to yaw are not always optimum for the site due to differences from For more information email the modeled site conditions. [email protected]. One of the yaw control improvements could www.windesco.com dynamically adjust the nacelle position of the turbine to maximize energy capture and minimize the wear and tear on the yaw drive components. Another one could use Turbine Rating (MW) 5 year NPV 5 year ROI Payback Period Assumptions: Portfolio capacity = 1 GW Power Price = $60/MWh Net Capacity Factor = 35% Discount Rate = 9% WWW.PESWIND.COM 89

Portable Offshore Accommodation Standardized or specialized solutions Offshore Accommodation www.ela-offshore.com

TALKING POINT The wind market revolutionized SHIFTing the limits © ZF With an increasing number of countries adopting a considerable share of wind into their energy mix, the wind market is maturing. Typical signs of this are the fact that incentives, like subsidies and flexible feed-in tariffs, are being reduced or are completely cut. Instead, target levels for investments in renewable energy capacity have been set. The wind market revolutionized itself with the introduction of an auction-based market mechanism, resulting in record lows in the Levelized Cost of Energy (LCOE), which could not have been imagined in the pioneering years of this industry. WWW.PESWIND.COM 91

TALKING POINT © ZF Wind turbines get segmented into an increasing number of torque segments. By 2027 the number of gearbox torque segments for onshore wind is expected to double. Therefore, ZF shifted its designs to a modular gearbox architecture that anticipates the growing number of torque segments In order to bring the LCOE down, the major onshore market segments, with different lifetime. The entire modular SHIFT platform players in the wind industry find themselves requirements, OEMs continue to introduce is extended across different torque ranges, in a race where the winner is the turbine with turbine designs with optimized LCOE by from SHIFT 3k; 3000-4000 kNm, over to the maximum annual power output for the reducing costs and boosting annual energy SHIFT 4k and SHIFT 6k, even up to SHIFT 7k; given site conditions at the sharpest possible production. As a result, wind turbines for the 7000-8000 kNm. Each SHIFT ‘xk’ platform of investment costs. Competitiveness is onshore wind market get segmented into an gearboxes is designed for a predefined defined in terms of flexibility and speed of increasing number of torque segments. market segment in terms of prevailing wind introducing new turbine variants with speeds and thus needed power ranges and ever-growing rotor diameters. Therefore, ZF shifted its designs to a capacity factors. modular gearbox architecture that ‘Go modular’ anticipates the growing number of torque The platform designs are also driven by segments: SHIFT. The modular platform logistical constraints and the ZF Wind Power anticipated the market trend structure provides greater flexibility in new interchangeability of components within and, since 2016, it’s been positioning itself as turbine development and allows further each SHIFT ‘xk’ platform is taken into the pioneer of the ‘modular platform optimization potential over the turbine’s consideration. This drives the torque approach’. In order to compete in different © ZF The evolution of the wind market, pushes the boundaries of innovation: the SHIFT 7k torque density surpasses the 200 Nm/kg barrier 92 PES WIND

TALKING POINT © ZF New innovations enable ZF to keep outside dimensions identical with growing torque levels. The real innovation lies in the size similarity to fit in the nacelle while doubling torque requirements positioning per platform as well as the lower different customer applications, which are levels. Concretely, the ring gear diameter of and upper ratio limit. Keeping the gear unit the typical long lead-time items in the supply ZF’s SHIFT 7k platform for the latest 6.xMW interfaces and outer dimensions identical chain. This enables ZF to react faster to turbines is not larger than that for state-of- across the torque range of a SHIFT ‘xk’ changes in order intake, as typically, multiple the-art 4.xMW turbines. The real innovation platform eliminates the need for major drive customers within the same platform are lies in the size similarity to fit in the nacelle train/nacelle redesigns over the lifetime of competing for the same type of wind sites. while doubling torque requirements. the wind turbine platform. Upon receiving new customer specifications, ZF offers the Moreover, it helps to minimize sudden The evolution towards higher torque ranges, platform member that most economically underutilization in ZF’s production plants and currently up to 8000 kNm, challenges the meets the application requirements. boosts efficiency and output per plant. supply chain to handle these requirements at Machine utilization is optimized for larger competitive costs, pushing the boundaries of In addition, using standardized building batch sizes, thus avoiding time lost when innovation. Seven years ago, 100 Nm/kg blocks inside the gearbox leverages the switching machine tools and programs. The torque density of a wind gearbox was the platform supply chain and operational SHIFT philosophy is well suited for global norm. It’s only been two years since ZF’s synergies. The building blocks offer platform manufacturing in different plants. A new SHIFT 6k raised the bar towards 175 Nm/kg. flexibility for future turbine power upgrades. modular gearbox platform is typically Today, the SHIFT 7k torque density As the SHIFT platform portfolio covers a launched in one manufacturing location, and surpasses the 200 Nm/kg barrier for a high torque range of 3000 kNm up to 8000 kNm then extended to a second or third location if speed gearbox configuration. ZF received for onshore and specific offshore the market requires. This makes SHIFT a the Wind Power Monthly gold medal in the applications, it offers customers a choice in truly global platform, with quality levels category ’drivetrain of the year 2020’ for this turbine designs and roadmaps dedicated to independent of its manufacturing location, major achievement. specific wind-market segments. and a supply chain optimized for local markets and best cost. SHIFT 7k leads the high power, high output The ZF platform approach has several onshore market segments as well as advantages for customers. Extensive SHIFT 7k: new torque density level hits dedicated offshore markets in the wind validation of a new gearbox platform is the market industry. The 7k four-stage version has three done only once. This massively reduces multiple-planet planetary stages – with 7, 6 time-to-market for a specific customer The trend towards more powerful wind and 4 planets respectively – and journal application, as time for design work as well turbines with increasing rotor sizes is bearings. Four-stage gearboxes have more as validation are reduced to a minimum. simultaneously paired with challenging components than their three-stage Variants of a platform only go through a target cost levels as well as limitations on equivalents, but most parts are smaller in size. limited validation trajectory based on nacelle transport in terms of dimensions and To meet global transportation standards, ZF specific changes in the design. weight. These physical design limitations in engineers took a maximum nacelle width of combination with cost target requirements 4.2 m into consideration. This resulted in a Furthermore, the modular platforms offer prompted ZF to rethink the gearbox designs. maximum outer diameter, i.e. the ring gear benefits in terms of logistics, supply chain, New technologies on different levels enabled diameter of the first stage, of 2.1 m, which is and operations. The standardized building ZF to keep outside dimensions identical e.g. kept the same over the SHIFT 4k, SHIFT 6k blocks within one platform are identical for ring gear diameters, with growing torque and the SHIFT 7k platform modules. WWW.PESWIND.COM 93

TALKING POINT ‘The key to the next level in torque density lies in further shifting currently accepted limits.’ Leveraging torque density while the data models take the spread on Another typical boundary in gearbox design tolerances in the chain of components i.e. is fatigue strength for castings. Standard Reaching a torque density level of gears, shafts, and bearings, into account. calculations typically limit the strength 200 Nm/kg* is a gradual approach that assessment approach. However, new requires a combination of technological By combining the simulation models with a influence factors on fatigue strength of elements: most obviously, the number of statistical data approach, ZF engineers cast iron, such as the effect of local gear stages and the number of planet gears succeeded in predicting the best achievable plasticization on durability, have been in the planetary stages, as well as the right load distribution factor in a multi-planet gear developed in the last decade. ZF engineers choice of bearings. Depending on the torque stage. In order to reach this target value have incorporated these new insights into level, the cost of the optimum number of repetitively, a ‘smart assembly’ process was existing calculation approaches. planets in a planetary stage can vary. established. This process takes measured However, it’s safe to say that more than 5 data from the components into account and What’s next: mechanics go digital planets will typically be used for high-torque selects the optimum combination for machines in at least the first stage of the assembly, a typical example of how an The torque density curve does not end at gearbox in the future. Depending on the Industry 4.0 approach leads to increased 200 Nm/kg. ZF sees potential in further required outer diameter of the gearbox, roller ratings for a gearbox. leveraging the value of data. This starts in the bearing solutions can still lead to competitive factory  and at suppliers, and the loop is closed torque density levels. But journal bearings Further steps in torque density require by the use of detailed field data. The key to the make it possible to build gearboxes with pushing boundaries even further without next level in torque density lies in further smaller outer diameters and thus reach jeopardizing reliability. When it comes to gear shifting currently accepted limits. SHIFT 7k higher torque density levels. materials, ZF detected and leveraged the sets an example of how consistently tracked potential in well-known materials, by moving manufacturing and quality data can help to Optimal load distribution across the different from synthetic material properties to shift limits in design without jeopardizing planets becomes an issue as the number of grade-specific material properties. For this, reliability. Therefore, ZF will continue to invest planets in the gear stages increases. ZF analyzed and tested, in gear component in a combination of system analysis, data Typically, loads are unevenly distributed to a test rigs,  how different material properties analysis, and consequent implementation in certain extent. However, ZF manages to influence fatigue strength of the gear smart production processes. arrive at a close-to-optimal load balance material. ZF now uses strict material between the planets. This is achieved by a specifications for steel suppliers. In www.zf.com/windpower smart combination of advanced simulation combination with establishing in-depth models and use of production data. The quality control processes on incoming steel, ZF Wind Power simulation models take all flexibilities and ZF was able to get this ‘ZF material deformations of the system into account, specification’ certified, thus allowing the ZF Wind Power is a global technology- use of higher fatigue strengths in gear driven manufacturing leader and * for high speed gearbox configuration rating calculations. pioneer in the global wind turbine gearbox industry. The company is leading the high- performance onshore segments with products up to 8000 kNm and is the first to exceed 200 Nm/kg torque density in compact designs. ZF delivered the world’s first offshore 9.5 MW wind turbine gearbox and has the largest global installed capacity of +8 MW offshore wind turbine gearboxes. Since the company entered the wind industry in 1979, ZF Wind Power has delivered more than 75,000 gearboxes, powering as much as 150 GW wind turbines, covering approximately 25 percent of the total installed capacity of gear-driven wind turbines worldwide. © ZF Technological innovations, like journal bearings make it possible to build gearboxes with smaller outer diameters and thus reach higher torque density 94 PES WIND

ZF Wind Power’s most powerful gearbox platform surpassed the 200 Nm/kg Torque Density barrier. This gearbox is developed to boost the annual energy production of new generation windturbines for high-speed wind markets. The SHIFT 7k variant complements the SHIFT platform which now covers the range from 3000kNm to 8000kNm, allowing customers to flexibly develop cost-effective turbine designs for all onshore and specific offshore wind classes. Visit: shifttowardsthefuture.com

THINK TANK The business case for energy storage systems in the APAC region Words: D r George Garabandic Principal Consultant & Energy Storage Lead APAC Anirudh Sharma Senior Consultant & Team Lead Energy Markets & Technology APAC The Asia Pacific (APAC) region is in the early stages of a transformational energy transition that requires progressive, widespread switching from fossil fuels to variable renewable energy sources (VRES) such as wind and solar power. This presents both opportunities and challenges. 96 PES WIND

THINK TANK The growth in installed and planned VRES increasingly commercially viable through determining adequate compensation generation capacity has provided investors technological advances, cost-learning measures for grid stability services, but the with increasingly attractive opportunities effects, and by offering services. main impediment is the current low and projects. With renewable energy Business Case 1: network upgrade referral penetration of renewable energy. Once generation expected to increase by 47% Studies1 have shown that capacity renewable energy penetration increases to between 2021 and 2030, the APAC region is avoidance or deferral is the biggest source the point where grid stability is a real rather witnessing a large increase in renewable of value for energy storage in the long run. than a theoretical cause for concern, there is energy project development. This is as a Energy storage complements other fixed likely to be an increasingly attractive result of the various technologies’ cost assets in the network and allows for better commercial scenario for ESS. competitiveness, as well as government planning and operation of the network. The Business Case 3: benefits of co-location actions to increase renewable energy addition of storage can defer transmission with RE penetration in the power generation mix. upgrades as it can address the issue of Investors and developers of RE can deploy congestion in the network by delivering ESS to offset any potential balancing costs Energy storage: business cases power during periods of low use and more they would otherwise incur due to available capacity. Without such a solution, intermittent generation. There is also a ESS are on the path towards becoming utilities would typically need to address the potential revenue generation stream in increasingly commercially viable, and our issue of congestion through network offering ancillary services such as FCR, three business cases from the APAC market upgrades and new transmission lines. provided such a framework exists in the have shown that storage can deliver value Therefore, this is a valuable service that can market to allow participants to bid their by enabling fast-start capabilities and peak be provided by ESS, but the key issue offerings. This is not the case in many parts shaving for VRES. The co-location of globally and in the Asia Pacific region, is the of Asia Pacific where markets can be storage and renewable energy sources also need for market rules to be adapted to cost-based and purely PPA oriented causing means investors and developers can deploy appropriately value such services and such services to not be cost-efficient while storage to offset any potential balancing incentivize ESS projects adequately. precluding new entrants in the market. Other costs they would incur due to intermittent Business Case 2: boosting grid stability as than ancillary services, there are also generation. In addition, we describe more VRE capacity is connected arbitrage opportunities from storing energy potential revenue generation streams by Utilities can deploy ESS while meeting their when it is being produced cheaply and providing ancillary services such as growing obligation to increase the number bidding to supply it when market prices will frequency containment reserves. and capacity of distributed energy resources result in profit. (DERs) connected to grids and maintaining Reducing costs Once the economics of a technology solution stability. Among the benefits that ESS can Lithium-ion battery costs continue to fall with compelling benefits make sense, it can offer here are fast-start, frequency while performance rises as the technology quickly gain traction and scale-up containment reserve, FCR, and peak shaving. moves rapidly down the cost-learning curve commercially. The three business cases The latter in particular is a key factor in and technical advances improve its described below centre on BESS becoming avoiding further carbon emissions. In many characteristics and efficiency for markets in the Asia Pacific region, high loads applications including utility-scale ESS. This during peak periods are covered by thermal points to lower capital costs, and hence or fossil fuel plants which are typically natural reduced financial risk, for tomorrow’s gas fired. Therefore, ESS can provide a Lithium-ion BESS compared with facilities of low-carbon alternative provided the system the same scale today. Or, looked at another is charged using renewable or low-carbon way, more storage capacity for the same cost power. Utilities and regulators in the Asia as today. Pacific region are in the process of Then there are the operational cost savings 1 L ong-run system value of battery energy storage in than can pass through to stakeholders in the electricity value chain and on to consumers. future grids with increasing wind and solar genera- It has been estimated that the Hornsdale tion - ScienceDirect Anirudh Sharma Dr George Garabandic WWW.PESWIND.COM 97

THINK TANK ‘Drawing on our experience of the regulatory and technology challenges and opportunities worldwide, DNV conducts analysis to assess the potential role and value of energy storage for the electricity supply systems, including identifying optimal configurations, sizing, and locations of potential ESS.’ Power Reserve led to more than AUD 100 in an investment and helps to even up configurations, sizing, and locations of million savings in South Australia’s energy information imbalances between potential ESS. costs in 2019, when the ESS also helped manufacturers and buyers across restore the grid to normality within minutes international boundaries. More than five million hours of energy of an interconnector equipment failure storage testing has been logged in our islanding the power system in that part of Warranties are also critical to the bankability US-based laboratory, which directly the country. review for an energy storage product or translates to experience that we deploy in project. For storage projects, they are the our role in supporting the successful Increasing bankability foundation on which all other supply, development of projects globally and in the commissioning, operational, service, and APAC region. This helps to compensate for The three business cases illustrated the financial documents are built. Even with the power and utilities industry’s general lack potential for ESS to supply multiple services significant improvements in cell and system worldwide of operational storage site data, a simultaneously. This creates the possibility technology alongside cost reductions, knowledge gap that represents a ‘growing of ‘layering’, selling multiple services to a warranty terms have become more complex. pain’ for a sector considering whether and customer to maximize the potential revenue how to use ESS technologies. stream, and thereby increasing the There is no industry standard yet, and the bankability of a storage project. battery degradation curves can vary widely Regulatory and governmental policy risks across various Lithium-ion battery cell types. Not only will layering, also known as ‘value When DNV reviews capacity warranties we Navigating the regulatory and governmental stacking’, counterbalance technology look closely at the annual degradation curve policy risks involved requires in-depth local challenges and regulatory risks, it also helps provided, how it is measured, how experience, insight, and human networks to strengthen the business case of a storage performance is calculated, and any other avoid making potentially costly decisions to project while also offering a risk- operational restrictions imposed on the invest in ESS in what could turn out to be the management tool based on diversifying project for the warranty to remain valid. wrong project in the wrong place at the sources of revenue. wrong time. Optimising energy storage projects Technology Bankability Conclusion Operating storage is significantly different Assessment of critical technologies is from operating fossil or RE power plants and The markets in the Asia Pacific region required in an energy storage project, such requires different strategies for each represent a complex mix of differing as a BESS, if the project is financially application. Drawing on our experience of the ambitions and levels of development when it leveraged. DNV’s well-established regulatory and technology challenges and comes to variable renewable energy source framework for technology bankability opportunities worldwide, DNV conducts such as wind and solar. This is reflected in assessment is well accepted by the analysis to assess the potential role and value their varying needs and propensity to investment and insurance industry. A of energy storage for the electricity supply encourage the addition of energy storage to bankability report reduces the risk exposure systems, including identifying optimal their energy systems, whether or not the storage has a grid-scale capacity and is ESS business cases Layering potential connected to national grids, or whether it forms an integral part of microgrids bringing Network upgrade deferral Low a reliable and cleaner energy to rural and remoter communities. Increased grid stability in light of higher volume of VRES in Higher the system As the energy transition in the region accelerates, there will undoubtedly be Benefits of ESS co-location with RE Highest more, and greater, opportunities for energy storage to play a key role in Layering potential of 3 ESS business cases overcoming the intermittency and curtailment barriers to renewables. www.dnv.com/power-renewables/ generation/wind-energy.html 98 PES WIND

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PES ESSENTIAL Breathing new life into ageing wind farms Words: M aggie McMillan, Sales Manager Renewables, Miros The global race to net zero is seeing an unprecedented drive to pursue offshore wind farm opportunities to ensure optimum operational integrity and longevity if they are to play their part in carbon neutrality goals by 2050 100 PES WIND