Cost Benefit Analysis and Argument in Favor of Replacement of Mechanical Turbine Control Wind Sensors
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The webinar discusses innovative solutions for wind turbine operations and maintenance, focusing on the advantages of Lufft's Ventus ultrasonic sensors over traditional mechanical sensors. It highlights the costs associated with sensor failures due to icing and the need for reliable, low-maintenance alternatives. The presentation emphasizes the long history and precision approach of Lufft in the wind energy sector while providing insights into the financial benefits of adopting advanced sensor technology.
Cost Benefit Analysis and Argument in Favor of Replacement of Mechanical Turbine Control Wind Sensors
- 1. #WindWebinar
- 2. #WindWebinar 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
- 3. #WindWebinar Introducing the Featured Speakers MODERATOR FEATURED SPEAKER Paul Dvorak Editorial Director Windpower Engineering & Development Abraham Aguilar Director of Business Development Lufft USA Inc.
- 4. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for precision · passion pour la précision
- 5. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Lufft history 1881 Present1989 Go#hilf Lu+ founded the company "Mech. Werksta# G. Lu+" in Stu#gart Part of
- 6. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Present: › More than 130 years of Business › Headquarters in Fellbach, Germany › Subsidiaries in USA and China › Part of a $20-Billion organizaQon
- 7. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec 1903: Lu+ became market leader in the field of metal barometer.
- 8. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Traffic Road Weather Mobile Weather Airports, Offshore, Trains Wind & Weather Renewable Energy Meteorology & Hydrology Building AutomaQon Industry Handheld devices for CalibraQon verificaQon Wall Mount-Control Cabinets Sensors/ Loggers TransportaQon sensors with Datalogging capabiliQes Present: Lu+ Covers a Wide Array of Industries and Markets
- 9. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Feedback from Wind Turbine O&M companies q OperaQons and Maintenance (O&M) company’s are looking for ways to reduce Cost and Increase producQon q Icing on Wind Sensors cause producQon loss q Need a simple to implement SoluQon q Added Costs with Mechanical sensors Replacements and Yearly RecalibraQon needs q Need a Low Cost, Robust Sensor (bo#om-line impact) q Meet Nuclear Regulatory Commission Requirements
- 10. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec » Halt-Report » Corrosion » VibraEon » Ice-free » IP66 Ventus Lufft Ventus for Wind Turbines ü Every sensor comes with a Factory CalibraEon cerEficate ü No Moving Parts, No Need to Recalibrate ü Dual Heaters prevents Ice from AccumulaEng, Prevents Rimming ü Digital and Analog Outputs directly from the sensor, for a simple soluEon ü Meets or Exceeds the NRC Regulatory Guide (RG) 1.23 requirements1 ü Wind DirecEon ± 2° ü Wind Speed ± 0.45 mph
- 11. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec 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
- 12. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Assumptions and Information for Analysis • Interviews with O&Ms reported: 40% of all mechanical sensors need annual replacement from failure • Wind turbine technicians on average make $23.46/hour2 • Five-hour maintenance Qme to repair or replace mechanical sensor3 • Signal CondiQoning needs to performed with addiQonal Wiring leading to addiQonal costs4 • Industry reports that icing occurs about 5x per year per farm (assumed to be 100 turbines) probability per turbine = 0.05 (5%) • InformaQon gathered informed us that $40/hour lost producQon x 24 hours x 14 days unQl a replacement sensor is delivered 1. h#p://www.nrc.gov/docs/ML0703/ML070350028.pdf 2. h#p://www.bls.gov/ooh/installaQon-maintenance-and-repair/wind-turbine-technicians.htm 3. h#p://analysis.windenergyupdate.com/operaQons-maintenance/role-sensors-wind-turbine-om 4. h#p://hps.ne.uiuc.edu/numug/archive/2000/Wastrack.pdf Sources
- 13. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $1,819.30 $2,547.02 $3,274.74 $4,002.46 $4,730.18 $2,112.30 Year 1 Year 2 Year 3 Year 4 Year 5 CumulaEve Cost Mechanical Ultrasonic Return on Investment on the 1st Year
- 14. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec How was $1,819 calculated for Mechanical Sensor? =300+50 + (23.46*5) + (40*5*0.4) + 400 + 200 + (40*24*14*0.05) Base Price for Mechanical Sensor Shipping Cost $23.45 technician cost/ hour x 5 hours Signal CondiQoning costs AddiQonal Wiring costs $40/hour lost producEon cost x 5-hrs for repair x 40% Annual Replacement due to failure $40/hour lost producEon x 24 hours x 14 days unQl replacement of sensor x 5% of probability of sensor icing
- 15. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec 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) Base Price for Mechanical Sensor Shipping Cost $23.45 technician cost/ hour x 5 hours Signal CondiQoning costs AddiQonal Wiring costs $40/hour lost producEon cost x 5-hrs for repair x 40% Annual Replacement due to failure $40/hour lost producEon x 24 hours x 14 days unQl replacement of sensor x 5% of probability of sensor icing
- 16. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $1,219.30 $1,707.02 $2,194.74 $2,682.46 $3,170.18 $2,112.30 Year 1 Year 2 Year 3 Year 4 Year 5 CumulaEve Cost Year Mechanical Return on Investment on the 3rd Year Assuming No AddiQonal Signal CondiQoning or Wiring Costs
- 17. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $1,819.30 $2,547.02 $3,274.74 $4,002.46 $4,730.18 $2,112.30 Year 1 Year 2 Year 3 Year 4 Year 5 CumulaEve Cost Mechanical Ultrasonic Return on Investment on the 1st Year
- 18. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $1,819.30 $2,547.02 $3,274.74 $4,002.46 $4,730.18 $2,112.30 Year 1 Year 2 Year 3 Year 4 Year 5 CumulaEve Cost Mechanical Ultrasonic CumulaQve Cost of past 4 years at 40% replacement due to failure
- 19. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec How was $2,112.30 calculated for Ventus Ultrasonic Sensor? =1945.00 + 50 + (23.46*5) + 0 + 0 + 0 + 0 Base Price for Ventus Ultrasonic Sensor Shipping Cost $23.45 technician cost/ hour x 5 hours Signal CondiQoning costs AddiQonal Wiring costs $40/hour lost producQon cost x 5 for repair x 40% Annual Replacement due to failure $40/hour lost producQon x 24 hours x 14 days unQl replacement of sensor x 5% of probability of sensor icing
- 20. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec IniQal Sensor Costs $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 CumulaEve Cost Mechanical (Heated) Ultrasonic
- 21. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec 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) Base Price for Mechanical Sensor Shipping Cost $23.45 technician cost/ hour x 5 hours Signal CondiQoning costs AddiQonal Wiring costs $40/hour lost producEon cost x 5-hrs for repair x 40% Annual Replacement due to failure $40/hour lost producEon x 24 hours x 14 days unQl replacement of sensor x 5% of probability of sensor icing
- 22. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $1,819.30 $2,547.02 $3,274.74 $4,002.46 $4,730.18 $2,112.30 Year 1 Year 2 Year 3 Year 4 Year 5 CumulaEve Cost Mechanical Ultrasonic (Heated) Assuming No AddiQonal Signal CondiQoning or Wiring Costs IniQal Cost is the Same for Heated as Non-Heated with addiQonal SC and Wiring costs with the same ROI within the 1 Year!
- 23. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $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 FiveYearCostPerTurbine Anemometer Type Power Production Losses: Icing Additional Wiring Signal Conditioning Power Production Losses: Mechanical Failure Maintenance 53%of cost due to Icing 48% of cost due to Icing
- 24. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Analysis of a 100- turbine wind farm with 1.5-3 MW turbines
- 25. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Ventus ultrasonic anemometer on wind turbines Ventus
- 26. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec American Wind Energy Association data Total number of operaQng uQlity-scale wind turbines: > 48,000 Source: http://www.awea.org/Resources/Content.aspx?ItemNumber=5059
- 27. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Save in Operational Costs and Increase Production Contact us: www.Lu+.com Abraham Aguilar Abraham.Aguilar@lu+usainc.com (888) 519-8443 (805) 618-2958
- 28. #WindWebinar Questions? MODERATOR FEATURED SPEAKER Paul Dvorak Editorial Director Windpower Engineering & Development pdvorak@wtwhmedia.com Abraham Aguilar Director of Business Development Lufft USA Inc. Abraham.Aguilar@lufftusainc.com
- 29. #WindWebinar q This webinar will be available at www.windpowerengineering.com & email q Tweet with hashtag #WindWebinar q Connect with Windpower Engineering & Development q Discuss this on EngineeringExchange.com Don’t Forget!
- 30. #WindWebinar