There is so much
growth in the renewable energy and in the oil & gas businesses that provide
growth opportunities for investors and insurers. We provide this information to make sure that
neither the investors nor the insurers take a financial bath as they pursue
these endeavors.
Explosive Growth in Wind Farm Capacity in late 2013 and 2014
Installations of new
capacity hit a record at about 13.1 gigawatts (GW) in 2012, but slumped to just
1.1 GW the following year, as developers rushed to bring their projects online
in 2012 to qualify. After great
uncertainty at the end of that year, the producer tax credit was revived on New
Year’s day 2013, for just one year.
However, the rules were changed so that any project that had started
construction by then would qualify.
That led to a boom in
development lasting into this year, and at the end of June about 14.6 GW of
wind capacity was under construction – a record level according to the American
Wind Energy Association (AWEA).
Currently, the cumulative U.S. wind energy capacity stands at about 80
GW.
Caution in the Wind: Rush to Install Poses Higher Loss Risks
We believe that the
rush to install the new capacity to take advantage of the production tax credit
should raise red flags for investors or insurers who would invest or insure
these installations. The wind farms have
been plagued with numerous failures the last twenty years: design,
construction, components failures, lack of proper operation & maintenance
(O&M) and so on. We believe that the
wind farms installed the last 18 months will have even higher failure loss ratios. Historical losses show that every time
projects are rushed to design and construction, failures occur at much higher
rate. The system reliability also is
reduced significantly due to components failing at a much higher rate. Significantly, the catastrophic failures (or
very high failures) typically increase when projects are rushed.
For example, as we
reported here https://sites.google.com/site/metropolitanforensics/cause-and-contributing-factors-of-failure-of-wind-turbines
this year, Siemens,
a main manufacturer of wind turbines, reported a charge of 48 million Euros for
inspecting and replacing defective main bearings in some onshore wind turbines. In addition, just few days ago, the new head of
Siemens’ global energy business said that the wind energy still needs the wind
production credit to be competitive with fossil fuels. The production tax credit for wind, in its
most recent form, allowed a tax reduction of 2.3 cents for every kilowatt hour
generated. It was first created in 1992,
and has been allowed to expire five times since 1998, creating a rollercoaster
boom and bust cycle for the US industry.
This
high loss ratio was the experience of several wind turbine manufacturers during
the early 1990s that were unable to maintain adequate quality controls during a
period of very high demand. Examples of
massive recalls involved the NEG Micon gearboxes and the Suzlon wind blades;
not to mention many others.
Wind Blade Failures
Another troubling
issue for the states is that these industrial wind facilities are seeing higher
failure rates than predicted. A recent
study found that there are about 3,800 wind blade failures a year with costs as
high as $1 million. Wind manufacturers
are under increasing pressure to deliver cost competitive technology resulting
in larger turbines with minimum unscheduled downtime and longer, lighter rotor
blades. The frequency and severity of blade failures varies from country to
country, and they result from lightning damage, manufacturing defects, and
human error.
Following Another Blade Failures, GE Identifies
'Suspect Population' In Turbine Fleet
Following a
thorough investigation, GE says a "spar cap manufacturing anomaly" is
to blame for the recent blade breaks at the Orangeville Wind Farm in New York
and Echo Wind Park in Michigan. The
company has identified other customers whose turbines are subject to the
anomaly and is working to perform blade replacements. A spar cap is a key structural element within
the blade that carries the bending load of the blade.
Oil leaking from a wind turbine in New York
Wind turbine system
reliability is a critical factor in the success of a wind energy project. Poor reliability directly affects both the
project’s revenue stream through increased operation and maintenance (O&M)
costs and reduced availability to generate power due to turbine downtime. Annual O&M costs include maintenance,
overhead, replacement parts, local taxes and fees, wages, and similar
expenses. Indirectly, the acceptance of
wind-generated power by the financial and developer communities as a viable
enterprise is influenced by the risk associated with the capital equipment
reliability; increased risk, or at least the perception of increased risk, is
generally accompanied by increased financing fees or interest rates or
increased insurance rates.
Wind
Farms have been plagued by Numerous Defects
GCube,
a provider of renewable energy insurance services has published a report
summarizing the most common wind energy insurance claims made in the United
States. The data based on 2012 US
reported claims, shows that blade damage and gearbox failure account for the
greatest number of losses – accounting for 41.4% and 35.1% of the total claims
reported. Although the majority of wind
turbine blade damage can be attributed to lightning strikes, delamination and
improper handling during the construction and installation phase are also
frequent and need to be addressed.
The
wind farm facilities may not be as reliable and durable as producers claim.
Indeed, with thousands of mishaps, breakdowns and accidents having been
reported in recent years, the difficulties seem to be mounting. Gearboxes hiding inside the casings perched on
top of the towering masts have short shelf lives, often failing before even
five years is up. Many wind turbines in
the United States now approach the five year critical interval. In some cases, fractures form along the
rotors, or even in the foundation, after only limited operation. Short circuits or overheated propellers have
been known to cause fires. All this
despite manufacturers' promises that the turbines would last at least 20 years.
Gearboxes
have already had to be replaced in
large numbers, the German Insurance Association is now complaining. In
addition to generators and gearboxes, rotor blades also often display defects. The insurance companies are complaining of
problems ranging from those caused by improper storage to dangerous cracks and
fractures.
One
major insurer who insured about 40 percent of the wind power generating
capacity in 2007, end up losing 70 percent of its wind business because of the
adjustment in its pricing/terms due to its experience with losses. The majority of the losses were associated
with Extra Business expense. The market
rates for operational risks used by this insurer were 0.20-0.30/100 for all
risk property damage policies and 0.30-0.50/100 for all risk Loss of
Profits/Business Interruption insurance.
Extra Business was approximately 50% of those rates. That insurer reported the cause of loss to
lightning (16%), breakdown (13%), wind damage (5%), unknown (25%). By component, the losses were caused by the
failure of gearbox (27%), blade (22%), generator (12%), and transformer (4%). From a severity standpoint, large claims have
been Property Damage related (such as, damage due to fire, lightning strikes,
structural collapse), while the frequency of the losses has been Extra Business
expenses (as we indicated earlier, the wind turbines operate about 30 percent
of the time and they are down 70 percent of the time). This operational frequency is lower or at the
lower end of the ranges than the ones advertised by the producers.
Many
times the replacement parts, both large and small, are not readily available to
deliver and install. Parts for older
models are not available because the technology is obsolete. The time to perform the repairs is long
because the locations of the turbines are remote, the roads are not in good
condition or not properly maintained and the repair crane may not be readily
available. Often times we see a supply
chain interruption, due to the global nature of this business where components
are manufactured in different parts of the world. This idling of the turbine means loss of
business/profits. Currently we estimate
that turbines are operational about 30 percent of the time. This is based on evaluation of tens of
thousands of loss records over the last twenty years both in the US and abroad.
Meanwhile,
damage to generators (10.2%) and transformers (5.1%) ranked third and fourth,
with damage to foundations coming in fifth.
Commensurately,
the top two most frequently reported causes of loss were cited as poor
maintenance (24.5%) and lightning strikes (23.4%). Design defect (11.5%), wear and tear (9.3%)
and mechanical defect (6.2%) featured in third, fourth and fifth when it came
to assessing and understanding the reason cited for the initial claim.
Even
among insurers, who raced into the new market in the 1990s, wind power is now
considered a risky sector. Industry
giant Allianz was faced with around a thousand damage claims in 2006 alone. According to this insurer, an operator has to expect damage to his
facility every four years on average, not including malfunctions and uninsured breakdowns.
Many manufacturers elected to build even larger
rotor blades to increase the capacity, but the strains they are subject to are
even harder to control. Even the
technically basic concrete foundations are suffering from those strains. Vibrations and load changes cause fractures,
water seeps into the cracks, and the rebar begins to rust. Repairs are difficult, as it is no use just
sealing the concrete cracks from above.
These stresses are even more obvious in the US, where the winds are even
stronger and more variable than the European winds.
Many
constructors of such offshore facilities in other countries have run into
difficulties. Danish company and world market leader Vestas, for example, had
to remove the turbines from an entire wind park along Denmark's western coast
in 2004 because the turbines were not sufficiently resilient to withstand the
local sea and weather conditions. Similar problems were encountered off the
British coast in 2005.
Many
insurance companies have learned their lessons and are now writing maintenance and
monitoring requirements -- requiring owners/operators of wind farms to replace
vulnerable components such as gearboxes every five years -- directly into their
contracts and to monitor the operation on a continuous basis. But a gearbox replacement can cost up to 10
percent of the original construction price tag, enough to cut deep into
anticipated profits. Indeed, many investors may be in for a nasty surprise. Several
thousand older facilities are currently due for new insurance policies.
Measuring the Wind Turbine Reliability – The ReliaWind Project
Few years ago, the ReliaWind project performed an
evaluation of the failure modes of the turbines and their associated
downtimes. The results showed that at
least a quarter of the time the root cause of the downtime cannot be determined. The main failure events are associated with
the generators (the frequency converter, the generator assembly, the LV and the
MV switchgear, and the transformer being the most frequently failed components),
the rotor module (the pitch system, the blades and the hub being the most
frequently failed components), the power control (sensors, communication system,
and safety chain being the most frequently failed components), the nacelle (the
yaw system being the most frequently failed component), the drive train (the
gearbox assembly being the most frequently failed component), structural module
(the tower being the most frequently failed component)and the auxiliary
equipment (electrical protection and safety, and the hydraulic system being the
most frequently failed components).
Gearbox: The majority of
the wind turbine gearbox problems that cause outages are due to bearing spall
and/or gear pitting. Annual oil sampling
of gearbox oil and bearing grease can be employed. Installing an oil debris sensor in the gearbox
lube oil system makes detecting bearing and gear damage at the early stage
easier and serves as a warning that additional borescope inspections are
necessary. Borescopes are commonly used
to document the condition of gear teeth and bearings within the gearbox and
should be used to inspect all gearboxes.
Blades: There are common
failure modes and four consistent areas where cracks may occur: the root,
leading edge, trailing edge, and tip. These
can be monitored by checking blade conditions, through inspection programs, and
through visual inspections, which should be done at least annually.
Generators: Electrical and
mechanical components subject to failure may include bearings, rotor winding,
stator, core insulation, slip ring, or commutator, to name a few. Root causes are various and include poor
design, improper installation, inadequate maintenance, overload, over speed,
excessive temperature, or excessive dielectric stress. Electrical current, flux, and power monitoring
techniques have been well developed and are now successfully used to monitor
wind turbine generators.
Substation Transformers: Using dissolved
gas analysis to check the breakdown of the insulation system is the most
cost-effective way to monitor transformer health. Various concentrations of
gases such as acetylene, methane, and ethane will indicate fault[s]. Analyzing the gases is effective for
identifying the root causes of problems and enables technicians to take
corrective actions before catastrophic failure.
Cables: Electric cable
systems can fail for a number of reasons. Low-voltage (less than 1kV ) cable
systems, commonly fail at the connectors due to overheating. One of the most effective tests for
low-voltage cable systems is the infrared assessment. A common practice is to minimize the number of
underground joints and use above-ground junction boxes. The junction boxes are a common failure point
and can be monitored using an infrared (IR) camera. In addition, junction boxes are perfect points
for fault indicators and predictive off-line insulation testing.
Condition
Monitoring and Testing
All machines will
deteriorate over time and fail. It is
just a question of when and to what degree the failure impacts operations
and/or project financials. Condition
monitoring of wind turbines should be comprehensive and include drive trains,
electrical, and power electronic components.
Monitoring systems
can play a vital role in highly reliable maintenance forecasting, which is
essential for improving turbine reliability and availability. A supervisory control and data acquisition
(SCADA) system can be used to monitor systems and provide data for all the
parameters measured within the nacelle. The
unit’s operational variables, operating parameters, and safety protection are
connected to this system, enabling the operator to dial in via modem and
connect to the system for remote operation.
The following items
can be routinely subject to condition monitoring and testing:
Temperature Monitoring: Temperature is an
age-old indicator of equipment health and can be used to diagnose component
wear prior to unexpected failure.
Vibration Monitoring: Sensors are
mounted on a turbine’s main shaft bearings, generator, and gearbox. A gearbox
with a planetary first stage and parallel shaft second and third stages,
requires a minimum of four accelerometers.
Oil & Grease Analysis: Oil analysis is
effective for measuring gearbox health and provides evidence of moisture,
viscosity breakdown, or presence of metallic particles in the lubricate that
will cause bearing or gear wear. Proper grease sampling methods are crucial for
comparing samples from one turbine to another or for trending samples from the
same turbine.
Generator: Electrical
testing of the generator will detect problems in the winding insulation. The
condition of generator cable terminations may also be inspected and signs of
previous arcing identified during testing.
Electronic controllers: Monitor voltage
and frequency of AC current in the grid. Any changes outside set variables will
allow the turbine to trip offline by functioning of protective electrical
devices for over/under current and over/under voltage.
End-of-Warranty Inspections
A typical wind
turbine warranty covers the first two to five years of the turbine’s 20-year
useful design life. Final inspection
reports should be planned in advance to address issues well before the warranty
expires. A visual inspection of the complete
turbine is recommended to document safety issues, the general turbine
condition, and component failures. A
common checklist should be developed with input from the operations and
maintenance staff. Checklists provided
by the OEM for regular maintenance can be a useful start.
Risk History
The early 1980's
brought tax law changes in the United States, and in California in particular,
which were designed to encourage development of wind generated energy and
reduce our dependence upon foreign petroleum products and potentially dangerous
nuclear energy. These tax "incentives", in the form individual
investment tax credits, required only that wind turbines be installed on a site
and connected to the utility grid – there was no requirement that the equipment
produce electricity, an omission in the legislation which turned out to be
nearly fatal to the industry.
The attractiveness
of these tax incentives, and the relatively short time period in which they
were available, caused a rash of untested wind turbine designs to be installed
on haphazardly developed wind farms. This resulted in a number of spectacular
serial equipment failures, and many multimillion-dollar insurance claims were
paid. The individual tax credits ceased to be available in 1986 as called for
in the legislation.
Available
technology at the time of this initial development, usually referred to as
"first generation" equipment, consisted of smaller (65 kW or lower)
capacity machines. Many of these turbines were designed and built in Europe for
their more constant and gentle winds. Others were designed by US aerospace
firms convinced that smaller, lighter designs were the answer. Installation of
many of these turbine designs in the California wind resource areas, where
winds can average 35 mph and up, and can peak at over 80 mph during the wind
season (May through October) proved to be disastrous.
The rotors, blades,
yaw systems, braking systems, shafts and gear boxes of a number of turbine
designs simply could not withstand the demand placed upon them, resulting in
large quantities of malfunctioning or broken machines.
Wind operators at
the time looked to the manufacturer's warranty, product efficacy, or their
Property and Boiler & Machinery insurance coverages for relief. The result
was heavy losses sustained by nearly all of the risk bearing insurance
companies involved.
Wind Turbine Insurance
Coverage Available
·
Contractual
Liability
·
Products
Defect
·
Serial
Defect
·
Power
Curve
·
Faulty
Workmanship
·
Parts
& Labor Backstop
·
SIR
Aggregate Cap
·
Earth
movement as a result of underground seismic activity
·
Difference
in Conditions (DIC)
·
Wind
Turbine Insurance Highlights
·
Risk
sharing or Fully Insured Programs Available
·
Serial
losses covered by “step-down” method vs. traditional “coverage suspensions”
·
Coverage
tailored to support the Turbine Supply Agreement
·
Coverage
tailored to support the Manufacturer’s Warranty
·
Terms
and limits can be tailored to virtually any risk
Current Industry Status
A wind turbine’s
reliability is dependent largely on the particular machine model, how well it
is designed, and the quality of manufacture. Reliability also varies with operating
environment, as it is the machine’s reaction to the wind environment that
determines the loading imposed on the components. The variety of potential component failures -
gearbox bearings, generator bearings and windings, turbine blades, power
electronics, gearbox torque arms, pitch drive electronics – indicate that the
operating conditions and load conditions for a large wind turbine and not
completely understood.
Installed Capital Costs
Cost of energy (COE)
is a key project evaluation metric, both in commercial applications and in the
U.S. federal wind energy program. To
reflect this commercial reality, the wind energy research community has adopted
COE as a decision-making and technology evaluation metric.
The 2011
NREL Cost of Wind report estimated average installed capital costs of $2,098 per kW of
wind power capacity, with a range of $1,400 to $2,900 per kW. This cost figure represents the costs of the
wind turbines and towers including transportation and installation, balance of
plant wiring and equipment, design and engineering costs, financing, and other
costs necessary to develop and build a wind power facility.
Assuming a
38 percent capacity factor and a discount rate of 8 percent, NREL calculated an
average installed capital cost per MWh of power output of $61. NREL’s 38 percent capacity factor may be reasonable
for a new power project built in a location with a high quality wind resource (which
is the kind of facility their “reference project” is intended to represent),
but it certainly appears high relative to data reported in the 2012 Wind Tech Report for existing
commercial projects. The Berkeley Lab’s
latest calculations of average capacity factors ranged from a low near 28
percent in 1999 to a high of about 34 percent in 2007. Since 2008, average capacity factors nationwide
have ranged from 31.1 to 33.5 percent.
Annual
Operating Expenses
The
2011 NREL Cost of Wind Energy Review employed an $11 per MWh estimate for annual operating
expense, with possible values ranging from $9 to $20 per MWh. Carrying over the adjustment in capacity factor
from 38 percent to 33 percent but keeping other assumptions the same results in
a slight increase in the estimates operations and maintenance cost, from $11
per MWh to $22 per MWh. Changes in the discount
rate do not affect annual operating expenses. The estimate of $11/MWh may also
be biased downward. The most recent Wind Tech Report indicated
a $10 per MWh average cost for annual operating expenses for projects built
since 2000, but it added that this estimate is likely below actual average operation
and maintenance costs. The Wind Tech Report stated that most wind power operators consider operating
and maintenance cost data information to be commercially sensitive and prefer
not to disclose it. As a result, the annual operating cost estimates reflect
only one-fifth of the capacity included in the installed capacity cost
calculation.
While
expenses faced by wind project developers are an important element of the
overall cost of wind power, addition of wind power to the power grid involves a
number of other costs. If a more reasonable estimate of the installed cost of
capital is $88 per MWh and operating costs are $21 per MWh, we can estimate a
reasonable LCOE for wind power near $109 per MWh rather than NREL’s estimate of
$72 — a more than 50 percent increase. Such costs include the expense of transmission
expansions needed to develop wind power, other grid integration expenses, and
added grid reliability expenses.
Based on
the above figures, the O&M costs can account for 10% to 20% of the total
COE for a wind project. The O&M
costs of the older units are greater than the ones for the newer units. Because
there is significant uncertainty in future O&M costs, when projects are
financed, sensitivities are frequently done on O&M costs. The difference between typical low and high
estimates can impact the COE and after tax return on investment approximately
10%. At present, the tax benefits
associated with wind energy contribute significantly to a project’s economics. As these benefits reduce over time, the
significance of uncertainty in O&M will increase. For example, while the
difference between low and high O&M estimates impacts after tax return
approximately 10%, it impacts pretax returns on the order of 20%. Thus, the
uncertainly in O&M costs will become more important to the industry as the
tax credits available to the commercial industry decline. From the research community’s
perspective, confidence in the O&M costs numbers is desirable to ensure
that the COE metrics being used to evaluate technology are appropriate.
Fires are major cause of wind farm failure
Main Wind Turbine
Risk Drivers include:
·
Technology continually pushed to larger outputs
·
Global Economy – Supply Chain – Lead Times
·
Repair times impacted by remote locations, road conditions,
& crane availability
·
Manufacturers are no longer in business
·
Parts for older models not available (obsolete)
·
Repairs/replacement parts
·
Losses can involve the entire nacelle
·
High wind speeds
·
Icing
·
Fire
·
Lightning
·
Vandalism and theft
Worldwide, fire is
the second leading cause of accidents in wind turbines, after blade failure,
according to insurance companies. As we
wrote earlier, in the US the gearbox failure is the leading cause of failure. The failure modes depend on the manufacturer
of the turbine and the other components of the wind farm and on the contractor
installing and operating/monitoring the farm.
Wind turbines catch
fire because highly flammable materials such as hydraulic oil and plastics are
in close proximity to machinery and electrical wires. These can ignite a fire if they overheat or
are faulty. Lots of oxygen, in the form
of high winds, can quickly fan a fire inside a turbine. Once ignited, the chances of fighting the
blaze are slim due to the height of the wind turbine and the remote locations
that they are often in.
Since the 1980s, when
wind farms were first constructed, the team found that fire has accounted for
10 to 30 per cent of reported turbine accidents. In 90 per cent of the cases, the fire either
leads to substantial downtime or a total loss of the wind turbine, resulting in
economic losses.
The researchers also
outline the main causes of fire ignition in wind turbines in the study. They are, in decreasing order of importance:
lightning strike, electrical or electronic malfunction, mechanical failure, and
errors with maintenance.
The number of wind
turbines installed grew three-fold between 2007-2013 and the instances of
reported fires in wind farms are increasing, say the researchers. However, the ratio of fire accidents per
turbine installed has decreased significantly since 2002.
According to the
researchers, the true extent of these fires has been hard to assess because of
the poor statistical records of wind turbine fires. In an effort to get a clearer picture about
the true extent of fires in wind farms, the team carried out an extensive
analysis of data from a wide range of sources. This included Government
reports, data from anti- wind farm lobbyists and information gathered by major
newspaper investigations.
The researchers
suggest a number of measures that can be put in place to prevent fires from
happening. These include "passive" fire protection measures such as
installing comprehensive lightning protection systems.
Other measures
include using non-combustible hydraulic and lubricant oils and building heat
barriers to protect combustible materials. Manufacturers are also advised to avoid using
combustible insulating materials and apply new monitoring systems to constantly
check the condition of machinery so that maintenance work can be carried out in
a timely manner.
The researchers also
suggest a number of "active" fire protection measures that can be
used to stop a fire before it takes hold or gets out of control. These include smoke alarm systems inside the
turbine, so that fire safety authorities can be alerted rapidly. The team also suggests suppression systems
that quickly douse the flames in water or foam.
Wind
Farm Monitoring
Wind-turbine failures
carry hefty claims costs so monitoring a wind turbine’s health can reduce
future risks, extend its life and increase reliability.
Wind-power projects
represent significant capital investments of many millions considering that a
wind farm can have tens of turbines with the cost per installed turbine of $2.5
million per KWh. So it’s no surprise
that, average claims for wind-turbine failures run between $200,000 and $600,000.
With such hefty claim costs, it is
important for insurers to understand the root cause of failures to reduce
future risks. To fully understand the
loss-adjustment process, METROPOLITAN has been hired by insureds, investors and
insurers to conduct forensic investigations of turbine failures. The forensic investigation helps shed light on
what contributes to a turbine’s overall health, and what extends its life and
increases reliability.
We have participated
in all phases of wind farm project development and financing, from inception to
the cost of lost electricity production. With claims carrying the large payouts cited,
the companies needed an in-depth investigator to accurately settle claims. We
are a good fit after identifying its independent technical capability, and its
understanding of forensics and design issues. METROPOLITAN also understands and shares similar
visions with our clients for the proactive mitigation of risk through
health-monitoring solutions to optimize risk management strategies. METROPOLITAN does not just investigates and
repairs or replaces parts, but gets a better understanding of what causes
failures. METROPOLITAN also offers an
unbiased, objective view of the forensic investigation because we work for all clients: insureds, insurers, investors,
governments, or individuals.
METROPOLITAN believes
monitoring turbine health plays a large role in managing risks and reducing the
cost of failures. Although the monitoring
software is not currently considered an industry standard in wind turbines, the
insurance company encourages clients to invest in it. Monitoring turbine health lets insurers
manage problems in advance rather than being caught flat-footed in response to
unexpected failures. We are looking at
incentives to promote the use of health monitoring software.
The insurance company
says a significant factor influencing operational performance and risk tends to
be environmental conditions. For
example, the company is occasionally approached at an early stage of project
development to advice on the insurance implications of turbine selection. An assessment includes advising on the risk
profile for a given turbine in a particular location. This usually occurs when a new turbine OEM is
looking to enter the market, or a project developer needs advice on the impact
of the new equipment on premiums and deductibles. The arrangement lets the insurance company
examine complex technical issues and helps clients make informed decisions.
Case Study of Failure
Analysis
The failure analysis
of the high-strength bolt at root position of a wind turbine blade was
conducted to find the cause of fracture. Detailed investigations using several
characterization techniques such as stress calculation, chemical composition
test, mechanical property test, metallurgical investigation, and fractography
analysis were performed to identify the cause of the bolt failure. Based on the theoretical calculation and
failure analysis, it could be concluded that the bolt failed by fatigue
accelerated by stress concentration while under low temperature. Practical suggestions were also given to avoid
similar failures.
Case Study of
Failure Analysis: GE Reveals Root Cause Of Recent Blade Failures
Following a
thorough investigation, GE says a "spar cap manufacturing anomaly" is
to blame for the recent blade breaks at the Orangeville Wind Farm in New York
and Echo Wind Park in Michigan. The company has identified other customers
whose turbines are subject to the anomaly and is working to perform blade
replacements. A spar cap is a key
structural element within the blade that carries the bending load of the blade.
Case Study of failure analysis of a wind turbine generator step-up transformer
Transformers also
fail frequently at wind farms.
Metropolitan performed an investigation into the recurring failures of
pad-mounted generator step-up transformers that have been experienced by an
energy firm at a wind farm in the United States. Observations indicate that the transformer
failures are typically a result of contaminated oil due to arcing within the
transformer expulsion fuse tube. To
determine the underlying cause of these phenomena, Metropolitan installed
digital monitoring equipment to capture electrical and thermal data at a
pad-mounted generator step-up transformer over a four-month period. Electrical data was also captured at the point
of interconnect between the wind farm and the local utility. The data captured in this time frame revealed
that high-current surges and current cycling frequently occurred due to the WTG
cycling on and off from the highly variable wind speeds in the area. High-current surges and current cycling places
thermo mechanical stress on the transformer and expulsion fuse links, which may
ultimately lead to the types of failures experienced at this location.
The Silence of the Bats
According to
citizens’ complaints, wind farms are certified bird and bat slaughterhouses,
where millions are clobbered, sliced and diced every year. Bats
may be lured to their deaths at wind farms because they think turbines are
trees in which they can find shelter, food and sex, according to new
research. About 600,000 bats are
estimated to have been killed by wind farms in the US in 2012. Bats may not have the cognitive ability to
differentiate wind turbines or other tree-like structures from real trees
either at a distance or at close range, the researchers at the USGS say.
The turbines also
kill many birds, including bold eagles.
In a settlement announced Friday, Nov. 22, 2013 Duke Energy will pay $1
million for killing 14 golden eagles over the past three years at two Wyoming
wind farms. The company says it pleaded
guilty to misdemeanor charges under the Migratory Bird Treaty Act. We know that the wind farm owners are trying
to develop ways of preventing the bats and birds from coming close to the
turbines, including the installation of flashing lights. Nobody wants this slaughtering to continue in
the name of green energy.
INSURANCE PROGRAMS
WARRANTY INSURANCE
A wind farm must
avoid the gap between property coverage and warranty coverage. A property
policy does not provide warranty coverage. A wind farm should purchase a separate
warranty policy.
By way of summary,
a property policy provides coverage for mechanical and electrical breakdowns,
subject to the policy’s exclusions and limitations, which may include:
·
Defects
or faults in material, workmanship, or design
·
Wear
and tear
·
Gradual
deterioration
·
Inherent
vice (e.g., hidden defects in the equipment or material that cause
deterioration)
·
Latent
defects
·
Serial
losses
Warranty policies,
on the other hand, provide coverage for product defects that lead to losses.
Warranty policies typically offer coverage for: five years with a “toolbox”
approach; product defect, serial defect, noise, power curve, and availability;
parts and labor “backstop”; self-insured retention/deductible buy-down options;
and warranty and loss control.
A wind farmer can
purchase an extended warranty policy from the original equipment manufacturer
(OEM). OEM warranties are sold on a per-turbine, per-year basis and cover the
full value of the turbine with little to no deductible. Or a wind farmer may
opt to purchase a third-party warranty policy that can be wrapped around the
turbine supply agreement to continue coverage supplied by the OEM. The
third-party warranty product can cover additional risks or modify the risks
covered in the original turbine supply agreement. The third-party warranty
covers serial defect, product defect, availability, parts, and labor. Optional
coverage for power curve and noise are also available and can be added by
endorsement. This is usually sold in “blocks” of limits that are usable for a
five-year period. The third-party warranty has an annual deductible structure.
Once a wind turbine
warranty expires, the operator may decide to assume responsibility for 100
percent of the costs and losses resulting from warranty-related incidents. In
other words, the operator decides to pay out-of-pocket for costs to secure the
effected turbine, obtain and ship replacement parts, hire and transport the
repair equipment, provide the labor for repairs, and assume lost income and
production tax credits. Or an operator may rely on the property insurance to
cover costs, which does not provide warranty coverage.
INSURANCE PRODUCTS TO
CONSIDER
A wind farm
operator should discuss the available insurance products with a broker who
specializes in wind farms and has the expertise to determine which products
best suit the project. The products available include:
Original equipment
manufacturer warranty
Extended warranty
Wind availability
insurance products
Builder’s risk
Transit/ocean cargo
Property all-risk
insurance, including business interruption
Equipment breakdown
Engineering and
loss control
Project performance
Supply bonds
Performance bonds
Professional
liability
General and
umbrella liability
Workers’
compensation
National resource
damage (environmental/pollution)
Principal Coverages
Insurers provide a
seamless policy for construction and operational phases. The key risks begin at
the construction phase, including transit of the equipment to site, erection
and testing, delay in start-up and finally operational property damage and
business interruption. The provide seamless, complete cover designed to avoid
any gaps or overlaps between the different phases of the project.
Material Damage
Construction and
erection
This cover protects
the insured, financiers, all contractors and sub-contractors and professional
consultants in respect of all risks of loss, destruction or damage to the
permanent or temporary works, materials, goods, plant machinery and equipment
used in connection with the design, construction, erection, commissioning and
testing of the project.
Property
This cover
indemnifies the insured and financiers against all risks of loss, destruction
or damage to the property and other assets owned by or the responsibility of
the insured.
Property forms do not provide
warranty coverage and can be ambiguous with exclusions or limitations so losses
are subject to underwriter’s acceptance or left for attorneys to litigate.
There are too many “gray areas” that leave projects exposed and put lenders and
investors at risk.
Property forms provide
coverage for the peril of mechanical and electrical breakdown if the failure is sudden and accidental and subject to
exclusions & limitations:
Defects or faults
in material, workmanship, or design:
Example - your
blades are cracking due to faulty materials or your bolts are not fastened
properly during construction and nacelle falls off tower. COVERAGE IS EXCLUDED
UNDER A PROPERTY POLICY!!
Wear and Tear:
Example - Your
cable brackets are failing due to a repetitive movement over a long period of
time and the cables are splitting and arcing. COVERAGE IS EXCLUDED UNDER A
PROPERTY POLICY
Gradual
Deterioration:
Example - Your
bearings are grinding over a long period of time which causes your gearboxes to
fail. COVERAGE IS EXCLUDED UNDER A PROPERTY POLICY
Inherent Vice:
Example - There are
hidden defects in the equipment or materials that cause deterioration and / or
damage. COVERAGE IS EXCLUDED UNDER A PROPERTY POLICY
Latent Defects:
Example – There are
hidden defects in material and/or workmanship not discoverable through general
inspection. COVERAGE IS EXCLUDED UNDER A PROPERTY POLICY
Serial Losses:
Example –
Development of a defect in equipment indemnity would be: 1st item 100%; 2nd
item 75%; 3rd item 50%; 4th item 25%; subsequent 0%. COVERAGE IS LIMITED UNDER
A PROPERTY POLICY
Warranties
have a positive impact on insurance premiums as they indemnify the equipment
system owner in the event a product defect that leads to losses. This was the
experience of several wind turbine manufacturers during the early 1990s that
were unable to maintain adequate quality controls during a period of very high
demand. Examples of massive recalls
involved the NEG Micon gearboxes and the Suzlon wind blades; not to mention
many others.
Financial
Advance Loss Of
Profits
This section of the
cover protects the insured and financiers against additional costs, expenses,
finance charges and loss of anticipated income following delays in completion
as a result of loss, destruction or damage to property insured under the
Construction and Transit cover.
Business
Interruption
Business
Interruption indemnifies the insureds and financiers against additional costs,
expenses, finance charges and loss of income following interruption to the
insured business as a result of loss, destruction or damage to property insured
under the Property cover.
Legal liability
Public and Products
Liability
This cover
indemnifies the insured and financiers (and where appropriate all contractors,
sub-contractors and professional consultants) against all sums for which they
may become legally liable (including claimants’ costs and expenses) in respect
of:
Death or bodily
injury to or disease contracted by any person
Loss of or damage
to property
Interference to
property or the enjoyment of use by obstruction, trespass, loss of amenities,
nuisance or any like cause; arising out of the insured projects and operations
Additional covers
In addition to the
cover shown above, there are a number of other important insurance products
available including:
Construction plant
and equipment
It is possible to
extend the project insurance program to include loss, destruction or damage to
construction plant and equipment, tools, personal effects of employees and
temporary buildings and contents used during the project. Such items are
normally the responsibility of the contractor and are either owned by him or
hired in specifically to undertake the project work.
Marine transit
Marine transit
insurance protects the insured and financiers against all risks of physical
loss, destruction or damage to materials, goods, plant and equipment intended
for use in connection with the project whilst in ocean or land transit
(including temporary off-site storage) within agreed territorial limits.
Transits are often for parts manufactured globally that are transported and
assembled locally. The cover is in force from the time the goods leave the
manufacturer’s premises until the time of arrival at the project site,
including any storage during the normal course of transit. If any intentional
storage coverage is required, this can be accommodated subject to material
information being supplied. The policy is normally designed to dovetail with
the Construction Insurance to ensure that there are no gaps in cover during the
transit operations.
Financial
Marine
consequential loss
If Marine transit
coverage is required, it would be necessary to combine it with cover for delay
in start-up (DSU) against additional costs, expenses, finance charges and loss
of anticipated income following delay in completion as a result of loss,
destruction or damage to items during transit. An indemnity period representing
the maximum probable delay to the EPC Contract as a result of damage to or loss
of such items will need to be selected. With the increasing role of project
finance, this coverage is particularly important for banks.
Legal Liability
Professional
indemnity
Contractors and
consultants normally fulfil the requirement for Professional Indemnity
insurance protection by way of annual renewable insurance programs. Although
there are alternative ways of procuring this cover, such as within a project
specific program covering all parties with a design responsibility, we would
not recommend this approach Rather, we advise to utilize the existing
insurances of the contractor and consultants, but require them to effect an
agreed level of Professional Indemnity cover and maintain it for a specified
period.
Employer’s
liability and workmen’s compensation
Most owners and operators
will need this insurance to cover the workforce who maintains the turbines.
There are particular risks here relating to employees working at height and the
obvious risks of maintaining offshore facilities.
Key risks
We have identified
the following key risk areas that you will need to consider as part of your
wind energy program:
Start-up delays
Delay to the
scheduled date of commencement as a result of damage to equipment while in
transit or installation damage.
Construction site
access
Developments in
remote or mountainous areas require careful preparation of roadways. For
example, we can assess gradients and access routes to prevent accidents and
delays during delivery of nacelles and blades.
Cable laying
The method and
preparation for laying cable around turbines and to substations will influence
the cost and the level of cover required. Most cables are laid underground in
well prepared trenches.
Wind force
disruption
During the
construction phase and also repair work, the impact of high wind conditions
requires careful evaluation. Clients need to ensure that they adhere to the
specific regulations relating to the use of cranes during high winds.
Lightning damage
This is the most
common exposure for operating turbines. We require proof that blades and towers
have good quality lightning protection. Working with a major blade supplier,
our team has measured and quantified blade strikes, helping to develop
strategies that mitigate damage levels.
Natural catastrophe
When tailoring
protection, a thorough evaluation of the local topography is needed. CNA
Europe’s experience is supplemented by studies of complex earthquake activity
worldwide. This enables us to produce comprehensive loss assessments and
post-loss procedures to help wind farm clients minimize expected loss cost and
therefore premiums.
Ground and soil
conditions
Knowledge of the
soil and geological surveys is a requisite for insurers when evaluating the
risks associated with piling for tower constructions or laying cable.
Technology
Whereas cover for
machinery breakdown is standard, series type losses are often excluded (i.e.
identical failures on multiple units). Proposed turbines with limited operating
experience may be considered as prototype. As a result, cover can be restricted,
affecting a project’s creditability and stakeholder investment. For risk
transfer, CNA Europe can help project owners demonstrate both to investors and
the markets that there is a robust risk management strategy in place. We also
assist developers review manufacturers’ guarantees, sourcing cover to
complement and avoid gaps in protection.
Substations and
power delivery
Time element losses
from the malfunction of the wind farm or substation down-time can become
disproportionately high. We work with our clients to reduce loss potential by analyzing
transformer and generator down time and the replacement of parts. This research
is already delivering beneficial and cost-effective solutions.
The aim is to
provide a holistic approach to the wind energy sector by combining multiple
lines of coverage within a single offering. We understand the complexities of
new and emerging technology and aim to provide tailor-made structures to
support the insurance needs of our wind energy clients.
Due Diligence for Wind Energy Projects
Project developers,
financial institutions, investors in or purchasers of a wind technology
company, turbine manufacturers – all stakeholders have a vested interest in a
technical due diligence review of a specific wind turbine model. METROPOLITAN brings extensive expertise and
experience to bear in providing a wide variety of turbine consulting services,
the nature of which is customized to a specific client’s needs.
Clients
call on these services for a variety of reasons. Some require an overview of the turbine market
to help them decide which turbine models to include in their wind farm
development plans; others want to purchase turbines for a specific project. There are also clients that are planning the
acquisition or financing of a wind farm project, or thinking of taking over a
turbine manufacturer. Whatever the
client’s motive, and this list is not definitive, the main aim of the turbine
consulting work is to provide an overview of the technical risks associated
with the technology and/or the business transaction in question as well as an
understanding of the possible mitigation measures.
METROPOLITAN’s
turbine consulting service is made up of three basic elements. The first is a wind turbine market overview,
including a review of a particular manufacturer's market share and of specific
turbine models available worldwide or by region. This is usually supported by a turbine
manufacturer overview with comments on the manufacturer’s capability to
manufacture, install and service wind turbines compared to industry standards,
previous performance and willingness to support products. Finally, a more detailed technical review
covers comments on the turbine technology compared to industry standards,
detailed component discussion, turbine design verification status according to
IEC standards or the like, previous performance, a technical risk summary and
classification of the turbine model as proven or unproven technology according
to pre-determined criteria. If a
specific project site is identified, METROPOLITAN can also comment on the
suitability of a specific turbine model for installation on that site.
Reviews
of the terms and conditions associated with the same turbines, or operational
warranties associated with performance, are typically provided as part of a due
diligence study, but can also be performed as part of a turbine review.
Construction
Oversight
METROPOLITAN provides
an objective analysis of a project's progress.
An independent
analysis of what progress has been made in construction of a renewable energy
project is vital – not only to check if work is going to schedule but also to
verify the validity of requests for payment from the construction company or
sub-suppliers. METROPOLITAN provides a third-party construction monitoring
service that puts clients in the picture when it comes to a project’s progress.
The main aims of
construction monitoring are to: review progress of construction work against
the project schedule, identify possible delays or cost variances, review
quality of work undertaken, verify milestone completion and certify progress
payments.
Generally speaking,
construction monitoring is conducted through periodic visits to the
construction site, usually on a monthly basis. More intensive monitoring may be required
during periods such as foundation construction or project completion. Clients may also request visits to other
locations such as manufacturing plants or ports to verify the availability or
delivery of components or equipment.
Construction
monitoring typically involves provision of regular reports summarizing the
findings of inspections and reviews and certification of main contract costs or
project milestones. The
construction-monitoring client will typically be an organization financing a
project or the owner of a wind farm under construction. In the latter case, the service is normally
part of a project due diligence. METROPOLITAN
has performed construction monitoring for a wide variety of clients, in many
locations around the world and can support new markets as they develop.
Interconnection of Wind Farm Components
METROPOLITAN
offers a holistic solution for interconnection based on a detailed
understanding of each required element.
The electrical
design of a windfarm is a critical element in delivering electrical power to
the grid resulting in revenue for the project. METROPOLITAN can offer investors and lenders
detailed assessments on all the electrical aspects of an onshore wind farm
based upon extensive experience and expertise. Our engineers would typically undertake
assessments on projects including:
·
Suitability
of the grid connection
·
Review
of technical aspects of connection agreement and any power purchase agreement
·
Grid
code review
·
Wind
farm electrical design assessment of the electrical plant
·
Electrical
Loss Assessments
·
Technical
review of equipment contracts
·
Electrical
aspects of turbine selection
The
scope and nature of the work depends on the development stage of the project,
from concept through consent and development through to operation. Interconnection can be offered as part of a
package or be electrical specific.
Failure investigation and root cause failure analysis
Premature
wear and failure of wind turbine components is widespread. The root cause of failures must be completely
understood in order to take appropriate corrective action. Our engineering expertise, processes, and
knowledge help to uncover root causes and assist operators in making the right
decisions to optimize project operations. We have conducted, and provided independent
review of, failure investigations ranging from full turbine collapse to
detailed inspection of internal gearbox components.
Careful
and thorough observations lead to evidence, and knowledge and experience lead
to insight. We combine our skills at
gathering evidence with our engineering insight to diagnose failures and
recommend appropriate corrective actions. We work with owners, operators, and equipment
manufacturers to determine failure mechanisms, assess the probability of
recurrence of the failure and associated risk exposure, and to develop
efficient and effective corrective action.
Our
failure investigation services include:
· On-site inspection
· Laboratory
analysis, including chemical analysis and metallography
· Mechanical testing,
including loads and vibration measurement
· Data analysis,
including statistical analysis
Inspections and audits
METROPOLITAN
provides independent assessment services at all stages of the project
lifecycle.
Whenever a wind
turbine and its components are inspected – at any stage from fabrication to
periodic monitoring on site or investigation of damage – the key benefit for
project developers, wind farm owners or investors is the objectivity of an
independent evaluation and the information the inspection report reveals. METROPOLITAN
employs highly qualified inspectors with all the wind turbine expertise and
experience to put clients in the picture.
Inspections
may be carried out at almost any stage in a project lifecycle. At a vendor’s premises equipment can be
inspected during or after fabrication, as it leaves the premises or on delivery
to a wind farm site. A number of
inspections are commonly performed on construction completion
or during the operation of a wind farm, e.g. rotor, nacelle, tower,
foundation and electrical system. Here, the main focus is on safety and
structural integrity. Other inspections may include offline condition
monitoring (vibration measurements), evaluation of lightning protection
measures, an oil analysis or video endoscopy.
Periodic
monitoring of all the turbines at a wind farm is recommended every two or four
years. This provides a client with a thorough review of each turbine’s
technical condition – information that can be useful in improving performance
or obtaining an independent opinion of a turbine’s condition prior to a key
commercial milestone (e.g. end of warranty of period). Inspections may also be
necessary to fulfill regulatory or insurance requirements.
If
something goes wrong, a damage investigation can be most helpful in identifying
the extent and type of the damage incurred and, crucially, in determining the
root cause of the problem.
An
independent damage investigation report is important in finding a technical
remedy to the problem, establishing responsibility for funding any repair work
and putting in an insurance claim. These investigations may also be crucial in
preventing further damage to other existing turbines.
End-of-warranty inspections
A
large number of wind turbines will have their warranty expiring soon. METROPOLITAN's hands-on approach helps owners
and operators obtain an independent assessment of the condition of the wind
turbines at end of warranty or in conjunction with extended service contract
negotiations. This information has
proved vital to inform business and contract discussions.
We conduct
end-of-warranty inspections for wind project owners to assess the condition of
their wind turbine equipment prior to the expiration of warranties or in
conjunction with extended-service contract negotiations.
Our
investigations include overall visual inspections and can include specialized
assessments such as:
·
Gearbox
videoscope inspection
·
Drive-train
vibration analysis
·
Detailed
blade inspection and imaging
·
Oil
and grease analysis
·
Corrosion
assessment
·
Operational
record analysis
·
SCADA
data analysis
·
Safety
analysis
·
Arc
flash hazard analysis
Setting
the industry standard through detailed engineering analysis and correlation of
assessment data, our comprehensive, independent reports maximize customer
return on investment in the assessment.
In
the event of warranty claims, we provide follow-up assessments to assist
project owners track warranty remediation.
Vendor
inspection
METROPOLITAN offers a
flexible inspection service based on client needs. This includes inspection of
complete structures or individual components.
METROPOLITAN can
perform inspection of equipment at Vendor's facilities. The inspected equipment may be complete wind
turbines but are commonly major components including blades, gearboxes and
towers. METROPOLITAN employs inspectors
located in all areas of the world with major turbine and component
manufacturing activities. This includes
Europe, Asia and the Americas.
The level of
inspection varies, depending on the Client's requirements, and ranges from
detailed quality inspection to more general work for expediting or payment
certification purposes. METROPOLITAN
provides Vendor Inspection services to Purchasers, Lenders, Insurers and
Investors and, in some cases, to turbine manufacturers for independent
verification purposes.
Performance & condition assessment
METROPOLITAN
provides advice to boost a wind farm’s bottom line.
Wind farm owners,
operators and lenders naturally want to know how their asset is performing –
and how to maintain and optimize its performance. METROPOLITAN provides the answers by
periodically assessing the performance and condition of a wind farm’s turbines
in terms of availability, key performance metrics, power curve and wind speed
against budgeted levels or expected trends. Through interpreting and validating
the results of power curve and availability warranty tests METROPOLITAN can
also help turbine manufacturers meet the performance obligations set out in the
turbine supply agreement.
The
monitoring service METROPOLITAN provides includes a review of operating reports
and other relevant information to reveal potential issues, and an in-depth
analysis of the high-resolution SCADA data to identify and investigate specific
phenomena such as underperformance or turbine malfunction. Specialist tools and
processes are used to qualify and quantify any production losses and identify
the root cause of a fault. METROPOLITAN can then advise the asset manager on
remedial solutions, including on-site guidance.
Operational
wind farm databases are compiled to establish availability and performance
trends and to get a clearer picture of any long-term risks. An objective
assessment of production, performance, reliability and availability statistics
allows an asset manager to benchmark the asset’s performance against the
industry standard. This facilitates the process of optimizing performance, minimizing
downtime and efficiently planning maintenance and spare part supply planning.
METROPOLITAN
offers the following specific services:
· SCADA data
management and archiving
· Wind farm
performance and condition trend analysis
· Fault analysis and
diagnostics
· Reliability, MTBF
and availability benchmarking
· Warranty and
liquidated damages calculations
· Analysis in
preparation for end-of-warranty or periodic inspections
· Root cause failure
analyses and remediation support
We
are actively researching new applications for condition monitoring and we are a
regular contributor to organization’s developing industry best practices.
Due diligence services
METROPOLITAN's
due diligence experts have advised on more global wind farm development than
any other company.
Understanding the
risks and mitigation measures associated with the wind industry is vital for
lenders and investors in wind farms. METROPOLITAN has unrivalled experience and
expertise in providing independent assessments for lenders and investors in
renewable energy projects and has acted in this capacity for more operational
wind farms than any other company.
METROPOLITAN
has been supporting investors in wind farms for nearly three decades. The
detailed technical understanding of its experts provides a solid basis for
informing intelligent decisions, regardless of the scale of the project or
investment or the lifecycle stage.
Project/portfolio
due diligence
METROPOLITAN provides
a solid underpinning of transactions based on years of experience.
Construction loan
financing, conversion of construction loans to term loans, financing and
refinancing of existing projects, equipment investment, portfolio debt and
equity investment, mergers and acquisitions: the wind industry is heavily
dependent on the financial community. Without financial support from banks or
investors, very few wind farm projects would ever be implemented.
The financial
community, for its part, is dependent on independent assessments of the
potential risks involved in wind farm projects. By identifying potential risks
and demonstrating ways of mitigating them, independent engineering consultants
can help a bank or investor to assess the commercial viability of a project’s
finance targets.
METROPOLITAN’s
project and portfolio due diligence service covers all of the
technical aspects of a wind farm project. Acting as an independent
engineer or client’s technical adviser, METROPOLITAN brings extensive expertise
and experience to bear in identifying potential areas of risk, searching for
possible means of technical and commercial mitigation, and working with the
finance targets to agree on the implementation of acceptable mitigations. In
this way, the financial community benefits from materially improved targets and
reduced risk.
METROPOLITAN reviews
all project-related reports, contracts, technical specifications and financial
models as well as the detailed design of certain features, for example the
turbine, turbine foundation and electrical network. Normally, due diligence
will be concluded by a report identifying potential risks and offering
suggestions for possible mitigations actions. If required, construction progress
can also be monitored and drawdown certification prepared.
Company
due diligence
METROPOLITAN provides
solid advice to inform smart investment decisions.
Technical due
diligence is a vital prerequisite for an informed decision on whether to
acquire or invest in all or part of a company. METROPOLITAN has the experience
and expertise required to perform technical due diligence on a wide range of
companies in the renewable energy field. This provides clients with the
information they need to take a sound decision on whether or not to invest, as
well as assess what price to pay.
The companies for
which METROPOLITAN has the necessary technical due diligence skills are
primarily technology designers and manufacturers (e.g. turbine manufacturers),
sub-suppliers (e.g. blade manufacturers) and developers or owners of renewable
energy projects. Work for companies in the latter category is usually similar
to that performed on project due diligence.
The methods used and
the scope of the work will naturally depend on the client’s brief. Generally
speaking, technical due diligence may include a market study, background
information on the target company and its market position, technology and
technological capability review (design team, etc.), intellectual property
review, analysis of competitors, facility review and SWOT analysis.
Mechanical & structural design
METROPOLITAN
offers a range of mechanical and structural design services for wind turbine
components from concept, through analysis, to preparation of design
documentation, specifications and certification-friendly deliverables.
METROPOLITAN
experts operate at the leading edge of developments in the strength analysis of
complex structural components which involve bearings, gears and bolts. They are
able to analyse all major components including rotor hubs, nacelle mainframes,
shafts and towers. For offshore structures, this includes foundations and
substation platforms. Analysis is conducted using rigorous yet rapid methods
that are well adapted to the design and development process.
Typical
activities result in the design and /or specification of the systems and
components below. The output includes 3D CAD drawings, technical specifications
and finite element modelling of components to provide strength calculations:
·
Blade
specification
·
Hub
·
Pitch
mechanical system specification
·
Main
bearing system specification (including housings)
·
Main
shaft
·
Main
frame including auxiliary frame
·
Gearbox
specification, including main shaft coupling
·
High
speed shaft and mechanical brake specification
·
Hydraulic
system specification
·
Yaw
system specification
·
Tower
with foundation insert
·
Rotor
lock specification.
Control
system design
METROPOLITAN is the
industry leader for the design of classical and multivariable control
algorithms which alleviate turbine structural loads and optimize energy
capture.
METROPOLITAN’s
turbine simulation and analysis experience helps to provide its clients with
control solutions that are both underpinned with a unique understanding of
up-to-date technology, and integrated into the overall turbine design process.
The algorithm designs it develops maximise energy capture and tailor the
dynamic response of the turbine structure in order to reduce rotor, drive train
and tower fatigue loading. All controller algorithms are delivered with
‘certification ready’ algorithm design documentation.
Implementation
services include provision of fully functional turbine controllers which run on
either PLC or industrial PC platforms, and deliver a range of field bus
protocols and low level I/O hardware options. The implementation of prototype
controllers is conducted in close collaboration with clients, and includes
significant technology transfer and training wherever appropriate, so that the
client is able to take the controller into series production following
commissioning and verification of the prototype. Specification documents that
cover the entire implementation process, including hardware processing, comms
and I/O, HMI & SCADA interfaces, supervisory control states and alarm logic
are always provided.
Performance
& load calculations
METROPOLITAN delivers
effective performance and load calculations to mitigate adverse loads, optimise
design and meet certification requirements.
Using Bladed, the
industry standard package developed in house over many years, METROPOLITAN
carries out comprehensive analysis of wind turbine performance and loading.
METROPOLITAN provides
a robust and reliable performance and load calculation service based on
in-depth knowledge of all relevant design standard and certification rules.
Blade aerodynamic design
METROPOLITAN
offers advanced aerodynamic design to optimise overall turbine design.
METROPOLITAN has
many years experience of establishing blade aerodynamic designs for maximum
energy yield across a broad range of turbine concepts and sizes.
Our
service delivers clients with a considered aerodynamic design solution
that also integrates controller algorithm optimisation, load calculation and
cost of energy optimisation.
Design
is tailored to accommodate client-specific requirements so that individual
goals and constraints are addressed. The design process takes into
consideration client requirements related to the following areas:
· Maximum chord
length
· Radial position of
the maximum chord length
· Maximum twist of
the blade
· Preferences for
aerofoils
· Structural loading
and dynamics
· Maximum deflection
· Absolute or
relative thickness distribution
Proposed
design solutions are always subject to detailed sensitivity analysis in order
to ensure their robustness.
Concept
Design
METROPOLITAN
offers advanced design which includes delivery of 3D CAD models.
METROPOLITAN’s
turbine design experts are highly experienced at assisting clients through the
Concept Design phase. They will help to establish a clients main design
requirements, key parameter values (rotor diameter, hub height, rated power
etc), and overall layout of a turbine and, where possible, they will also
select major component sizes and ratings and, in certain key areas, the actual
component supplier and model.
The
output of the concept design phase includes a turbine concept layout in CAD
form, as well as all the necessary information required for the following
Preliminary Design phase.
The
concept design process typically commences with a kick-off meeting to formalise
the concept requirements. Development of the control and safety concept is
followed by the creation of a preliminary Bladed model of the wind turbine
which establishes baseline loading information for selection of critical
components. The concept is then developed by considering the system layout and
reviewing the availability and capability of key design driving components.
A Concept Design Specification document is prepared which typically
includes:
· Basic design
parameters
· Required design
standard, certification rules and wind class
· Definition of
control and safety concept
· Bladed model and
baseline loads
· Key component and
sub-system selection and definition
· Power train
arrangement
· Layout and general
outline of all major structures and bearings
· Dimensions and mass
estimates of major components
· CAD model of design
concept.
Metropolitan Engineering, Consulting & Forensics
(MECF)
Providing
Competent, Expert and Objective Investigative Engineering and Consulting
Services
P.O. Box
520
Tenafly,
NJ 07670-0520
Tel.:
(973) 897-8162
Fax:
(973) 810-0440
E-mail:
metroforensics@gmail.com
Web
pages: https://sites.google.com/site/metropolitanforensics/
https://sites.google.com/site/metropolitanenvironmental/
http://metroforensics.blogspot.com/
We are happy to announce the launch of our twitter account. Please make
sure to follow us at @MetropForensics or @metroforensics1
Metropolitan appreciates your business.
Feel free to recommend our services to your friends and colleagues.