Wind O&M Data Pack: Turbine Failure Rates & Costs

Transcription

1 Wind O&M Data Pack: Turbine Failure Rates & Costs B U S I N E S S I N T E L L I G E N C E Wind O&M Data Pack: Turbine Failure Rates & Costs 2017

2 Wind O&M Data Pack: Turbine Failure Rates & Costs As part of our research into failure rates, costs and downtime on US Wind Farms, we have built a model which estimates lifetime costs of scheduled maintenance for a wind farm in the US. The input data used to build this data pack is a 210MW wind farm made up of 105 2MW turbines of 80 metres in height. The tables below show component risk factors, periodic maintenance costs, failure scenarios and supply chain factors. CMS options play an increasingly important role in both mean time to repair and the time between failures. As a result they have a large impact on costs. These are also taken into account. Finally the data pack provides major component lifetime O&M cost for the wind farm. Input Farm Size [MW] Scheduled maintenance cost 210 Turbine Capacity [MW] 2 Turbine Age [yrs] 0 Tower Height [m] 80 Frequency per year Cost per action per turbine Reduced cost Lifetime cost per farm 2 6,000 5,100 21,420,000

3 Components Replacement cost Failure rate (%) Failures per 100 parts by year 20 Reference scenario Total failures in 20 years (total farm) Component risk factors Average Downtime per failure Days per failure Average downtime losses per faiure Total downtime losses for the rest of the lifetime Labor Cost Crane cost per failure per failure Gearbox 220, ,029 20, ,000 Blades 120, ,723 25,000 45,000 Generator 130, ,453 7,000 61,000 Supply chain risk factors Spare in stock / No spare Available / No spare Lead time days Distance to manufacturing facility (if no spare available) Close/ Medium/ Remote Time for transportation days Gearbox No Spare 70 Remote 15 Blades No Spare 105 Remote 15 Generator No Spare 70 Remote 15

4 Gearbox CMS factors (per turbine) Capital Sensor Cost (including installation) per turbine Monitoring type Cost Reduced cost (economies of scale) Oil+vibration+temperature 20,000 18,000 Annual cost (O&M) per turbine Fixed cost Reduced cost (economies of scale) Detectability Efficiency Vibration+temperature 10,000 9, Temperature Blades Optical 15,500 13, Generator Temperature lifetime maintenance cost for the farm () Preventive lifetime maintenance cost assuming secondary damage () Gearbox 3,420,829 3,762,912 lifetime maintenance and CMS operation cost for the farm () Predictive Monitoring type 3,910,603 Oil + vibration + temperature 3,444,192 Vibration + temperature 2,915,926 Temperature Blades 5,241,963 5,504,061 5,930,817 Optical Generator 2,224,253 2,379,950 1,909,027 Temperature

5 We have also looked at failure rates across different turbine technology types and designs. The graph below shows major component failure rates for all types of turbines in our dataset during the first ten years of operations. Different failure modes have different repair times, ultimately leading to different costs. 1.2 Failure rate for all turbines Failure rate Year 1-5 Year 6 Year 7 Year 8 Year 9 Year 10 Yaw Turbine transmission Structure and machinery enclosure External lightning protection Control and protection Central hydraulics Blade adjustment Generator Rotor Drive train Turbine

6 The failure modes for all turbines are shown below. Mean Time To Repair for all Turbines 3.9 3,6 3.3 MTTR in days Year 1-5 Year 6 Year 7 Year 8 Year 9 Year 10 Yaw Turbine transmission Structure and machinery enclosure External lightning protection Control and protection Central hydraulics Blade adjustment Generator Rotor Drive train Turbine More information on component failure rates, O&M performance, operator insight and asset optimisation strategies are contained in our Wind O&M Report The report looks at all major turbine types including Danish Concept, Variable Resistance, DFIM and Direct Drive. We also have data on different turbine sizes and capacities worldwide and our market leading report contains proprietary research and survey data from global operators. New Energy Update Partnered with Wind Energy Benchmarking Services to deliver failure rate insight in the Wind O&M Report If you would like to provide feedback on the Data Pack or have any questions about the report please contact: Louis Vye, Business Intelligence Manager, New Energy Update +44 (0) lvye@windenergyupdate.com