cost benefit analysis and argument in favor of replacement of mechanical turbine control wind...

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q  This webinar will be available afterwards at www.windpowerengineering.com & email

q  Q&A at the end of the presentation q  Hashtag for this webinar: #WindWebinar

Before We Start

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Introducing the Featured Speakers

MODERATOR FEATURED SPEAKER Paul Dvorak Editorial Director Windpower Engineering & Development

Abraham Aguilar Director of Business Development Lufft USA Inc.

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a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for precision · passion pour la précision

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a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for precision

Lufft history

1881 Present 1989

Go#hilfLu+foundedthecompany"Mech.Werksta#G.Lu+"inStu#gart

Partof

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Present:›  Morethan130yearsofBusiness›  HeadquartersinFellbach,Germany›  SubsidiariesinUSAandChina›  Partofa$20-BillionorganizaQon

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1903: Lu+becamemarketleaderinthefieldofmetalbarometer.

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Traffic

RoadWeatherMobileWeatherAirports,Offshore,Trains

Wind&Weather

RenewableEnergyMeteorology&HydrologyBuildingAutomaQon

Industry

HandhelddevicesforCalibraQonverificaQonWallMount-ControlCabinetsSensors/LoggersTransportaQonsensorswithDataloggingcapabiliQes

Present:Lu+CoversaWideArrayofIndustriesandMarkets

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Feedback from Wind Turbine O&M companies q  OperaQonsandMaintenance(O&M)company’sarelookingfor

waystoreduceCostandIncreaseproducQon

q  IcingonWindSensorscauseproducQonloss

q  NeedasimpletoimplementSoluQon

q  AddedCostswithMechanicalsensorsReplacementsandYearlyRecalibraQonneeds

q  NeedaLowCost,RobustSensor(bo#om-lineimpact)q  MeetNuclearRegulatoryCommissionRequirements

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» Halt-Report» Corrosion» VibraEon»  Ice-free»  IP66

Ventus

Lufft Ventus for Wind Turbines ü  EverysensorcomeswithaFactoryCalibraEoncerEficate

ü  NoMovingParts,NoNeedtoRecalibrateü  DualHeaterspreventsIcefromAccumulaEng,PreventsRimmingü  DigitalandAnalogOutputsdirectlyfromthesensor,forasimplesoluEonü  MeetsorExceedstheNRCRegulatoryGuide(RG)1.23requirements1

ü  WindDirecEon±2°ü  WindSpeed±0.45mph

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Cup AnemometerUltrasonic Anemometer Vane Anemometer

•  No moving parts•  Includes temperature control for icing events•  Lifespan of approximately 5 years•  Higher upfront cost•  Provides more turbine controls for higher

accuracy and power generation•  Provides wind speed and direction•  Includes Digital and Analog communication

protocol

•  Moving mechanical parts are subject to weathering

•  Weight and inertia of moving cups may negatively impact accuracy of reading

•  Low system power requirement•  Inexpensive upfront cost•  Mechanical failure rate is as high as

once per year•  May have frequent recalibration

requirements

•  Low upfront investment cost•  Subject to same mechanical failure issues as cup

anemometer•  Freezing temperatures and weather-related buildup

require replacement or repair•  Higher starting threshold•  Requires signal translation/conditioning: pulse

counter input and analog input required•  Noise from analog signals reduces accuracy in

readings

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Assumptions and Information for Analysis •  InterviewswithO&Msreported:40%ofallmechanicalsensorsneedannualreplacementfromfailure•  Windturbinetechniciansonaveragemake$23.46/hour2

•  Five-hourmaintenanceQmetorepairorreplacemechanicalsensor3

•  SignalCondiQoningneedstoperformedwithaddiQonalWiringleadingtoaddiQonalcosts4

•  Industryreportsthaticingoccursabout5xperyearperfarm(assumedtobe100turbines)probabilityperturbine=0.05(5%)

•  InformaQongatheredinformedusthat$40/hourlostproducQonx24hoursx14daysunQlareplacementsensorisdelivered

1.  h#p://www.nrc.gov/docs/ML0703/ML070350028.pdf

2.  h#p://www.bls.gov/ooh/installaQon-maintenance-and-repair/wind-turbine-technicians.htm3.  h#p://analysis.windenergyupdate.com/operaQons-maintenance/role-sensors-wind-turbine-om4.  h#p://hps.ne.uiuc.edu/numug/archive/2000/Wastrack.pdf

Sources

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$1,819.30

$2,547.02

$3,274.74

$4,002.46

$4,730.18

$2,112.30

Year1 Year2 Year3 Year4 Year5

CumulaE

veCost

Mechanical Ultrasonic

ReturnonInvestmentonthe1stYear

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How was $1,819 calculated for Mechanical Sensor?

=300+50+(23.46*5)+(40*5*0.4)+400+200+(40*24*14*0.05)

BasePriceforMechanicalSensor

ShippingCost

$23.45techniciancost/hourx5hours

SignalCondiQoning

costs

AddiQonalWiringcosts

$40/hourlostproducEoncostx

5-hrsforrepairx40%AnnualReplacement

duetofailure

$40/hourlostproducEonx24hours

x14daysunQlreplacementofsensorx5%ofprobabilityof

sensoricing

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Brings the cost to $1,219.30 for the 1st year of a Mechanical Sensor?

=300+50+(23.46*5)+(40*5*0.4)+0+0+(40*24*14*0.05)


ShippingCost


SignalCondiQoning

costs




duetofailure



sensoricing

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$1,219.30

$1,707.02

$2,194.74

$2,682.46

$3,170.18

$2,112.30


CumulaE

veCost

Year

Mechanical

ReturnonInvestmentonthe3rdYear

AssumingNoAddiQonalSignalCondiQoningorWiringCosts

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$1,819.30

$2,547.02

$3,274.74

$4,002.46

$4,730.18

$2,112.30


CumulaE

veCost


ReturnonInvestmentonthe1stYear

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$1,819.30

$2,547.02

$3,274.74

$4,002.46

$4,730.18

$2,112.30


CumulaE

veCost


CumulaQveCostofpast4yearsat40%replacementdueto

failure

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How was $2,112.30 calculated for Ventus Ultrasonic Sensor?

=1945.00+50+(23.46*5)+0+0+0+0

BasePriceforVentus

UltrasonicSensor

ShippingCost$23.45

techniciancost/hourx5hours

SignalCondiQoning

costs


$40/hourlostproducQoncostx5forrepairx40%AnnualReplacementduetofailure

$40/hourlostproducQonx24hoursx14daysunQlreplacementofsensorx5%ofprobabilityofsensoricing

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IniQalSensorCosts$900.00=900+50+(23.46*5)+(40*5*0.4)+

400+200+(40*24*14*0.05)

$2,419.30

$3,387.02

$4,354.74

$5,322.46

$6,290.18

$2,112.30

Year 1 Year 2 Year 3 Year 4 Year 5

CumulaE

veCost Mechanical (Heated) Ultrasonic

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Brings the cost to $1,819.30 for the 1st year of a Mechanical (Heated) Sensor?

=900+50+(23.46*5)+(40*5*0.4)+0+0+(40*24*14*0.05)


ShippingCost


SignalCondiQoning

costs




duetofailure



sensoricing

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$1,819.30

$2,547.02

$3,274.74

$4,002.46

$4,730.18

$2,112.30


CumulaE

veCost

Mechanical Ultrasonic(Heated)AssumingNoAddiQonalSignalCondiQoningorWiringCosts

IniQalCostistheSameforHeatedasNon-HeatedwithaddiQonalSCand

WiringcostswiththesameROIwithinthe1Year!

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$6,308

$4,335

$6,948

$2,112

$-

$1,000

$2,000

$3,000

$4,000

$5,000

$6,000

$7,000

Mechanical (non-heated)

Mechanical (heated) Mechanical (with communication

protocol)

Ultrasonic Fiv

e Ye

ar C

ost P

er T

urbi

ne

Anemometer Type

Power Production Losses: Icing

Additional Wiring

Signal Conditioning

Power Production Losses: Mechanical FailureMaintenance

53%of cost due to Icing

48%ofcostduetoIcing

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Analysisofa100-turbinewindfarmwith1.5-3MWturbines

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Ventusultrasonicanemometeronwindturbines

Ventus

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American Wind Energy Association data

TotalnumberofoperaQnguQlity-scalewindturbines: >48,000

Source: http://www.awea.org/Resources/Content.aspx?ItemNumber=5059

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Save in Operational Costs and Increase Production

Contactus:www.Lu+.com

AbrahamAguilarAbraham.Aguilar@lu+usainc.com(888)519-8443(805)618-2958

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Questions?

MODERATOR FEATURED SPEAKER Paul Dvorak Editorial Director Windpower Engineering & Development [email protected]

Abraham Aguilar Director of Business Development Lufft USA Inc. [email protected]

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q  This webinar will be available at www.windpowerengineering.com & email

q  Tweet with hashtag #WindWebinar

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