Category Archive Wind Turbines

Turbine Data Storage & Analytics

Turbine Data Storage & Analytics

KK Wind Solutions (KKWS) has more than 35 years of experience working with wind turbine systems and subsystems. More than 65% of offshore wind turbines are equipped with KKWS solutions, in over 25.000 turbines.

KKWS asked PowerCon Embedded, to help them find a solution for backing up data from their turbine logging system. They were concerned, that their data logger could get full and they might lose some that that may be crucial in one of their projects.

Over 1.5 million data points were saved every hour, for one turbine, resulting in 30-40 million entries each day. The amount of data quickly increases when more turbines are added, adding to the necessity of a Big Data solution

KKWS asked PowerCon Embedded, to help them find a solution for backing up data from their turbine logging system. 

The requested solution should be able to back up all the data, store it in an efficient way and make it easily accessible to the various stakeholders taking part in the project. The cloud based solution, should provide easy interface to the data and integration with Data Visualisation and Data Analytics tools, for Big Data.

After a collaborative technology investigation process, whereby several database types and cloud architectures were discussed, a solution was agreed upon. 

The Proof of Concept (PoC) consisted of a cloud architecture setup in Microsoft Azure, a Time-Series Database implementation, which allows for efficient and quick storage of Big Data, a backup agent that gathers the data from the turbine and a Data Analytics layer connected with the Time-Series Database.

The Time-Series Database chosen, came bundled with Data Analytics and Data Visualisation tools, allowing for the Big Data to be backed up, but it also provides easy access to the data and analytics to relevant stakeholders in the project.

Through a great collaborative effort with KKWS, PowerCon Embedded managed to plan, develop, implement, document and hand-over a fully functional PoC in less than 2 months. 

The cloud based solution, albeit a PoC, is designed to be easily scallable and depending on the outcome of the PoC it can be extended to all the turbines runnig KKWS data logging systems, resulting in a truly Big Data setup, with Data Analytics and Visualisation tools.

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PowerCon Embedded helped us carry out an technology assessment and architecture design of a cloud based data collection and analysis platform. They managed to design the architecture, select technologies and develop a working prototype within a very short time period.

 

We experience PowerCon Embedded as very easy to cooperate with, they are competent and always deliver as agreed.

 

Rasmus Nielsen

Director, Software Engineering

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Multi-Level Converter

Multi-Level Converter

KK Wind solutions, POWERCON, AALBORG UNIVERSITY

The aim of the project is the development and manufacturing of a multi megawatt converter system that not only complies with state-of-the-art requirements and features within the wind turbine industry, but also significantly lowers the cost compared with the prices known from the industry today.

The project succeeded by developing a new Converter system that reaches the targets in terms of efficiency and cost, by achieving a medium voltage system with the same cost as a low voltage design. The project demonstrated scalability with a kW demonstrator and efficiency and cost with a full scale 6MW version.

The main challenge for the project is to combine the technical benefits from various known systems and expand these to the future turbine needs

Looking at the market today the common systems available are divided into cost competitive, low-voltage, two-level converter systems, and various medium-voltage systems that in some applications can offer increased system efficiency but normally also at a higher cost.

Multi-level Controller Advantages

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The main challenge for the project is to combine the technical benefits from various known systems and expand these to the future turbine needs without compromising with the overall driver of keeping the cost of the system at a minimum.

 

The Modular Multi-level Converter shows several advantages, such as scalability, high modularity, low switching losses, low Total Harmonic Distortion and high reliability. Thanks to these benefits, this topology has become a promising solution in several applications, like in High Voltage Direct Current, static compensators and in high-power motor drivers.

This project is contributing to the long-term objective to convert the Danish energy system to be 100 % based on renewable energy, of which the exploitation of wind energy has been a key driver

 

Also new market possibilities such as Onshore Power Systems for the maritime market are in progress since the multi-level design also provides some interesting features towards supply and charging of electrical and hybrid ships.

For system verification and future cooperation, we are looking for a suitable test partner.

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HIL System

KK Wind Solutions is developing control systems for both new turbines and for retrofit of existing turbines.

 

In order to speed up project execution, to ensure successful retrofit of two wind turbines types and to be ready for the wind season, PowerCon Embedded was contracted to provide two services:

 

– Make a HW-in-the-loop (HIL) test system, to simulate the drivetrain, generator, thyristor and the grid

– Increase capacity of the SW application team by applying resources and knowledge

KK Wind Solutions accelerated execution on a high-profile customer project in the green-tech business. PowerCon Embedded delivered a highly skilled development team that boosted progress and ensured timely deliverables.

Based on PowerCon Embeddeds Project Accelerators and customized interfaces, HIL system 1 was ready within just 6 weeks, and HIL system 2 was ready after additional 12 weeks. HIL1 is a simple system simulation while HIL2 has more advanced simulation of the power system.

 

The HIL systems was turn-key projects, which was developed and tested in PowerCon Embeddeds laboratories, and subsequently integrated at KK Wind Solutions test setup. The HIL systems involved HW design, FPGA design, matlab modeling with code generation and SW development.

With the experience and domain-knowledge of the PowerCon Embedded team within wind turbine applications and wind turbine integration, PowerCon Embedded was able to contribute immediately to development, test, integration and configuration of multiple wind turbine subsystems. The team worked seamlessly with the customer project team and had responsibility for its own deliverables. The job was handled on-site/off-site as best fitted the individual tasks and the needs of the customer.

 

Thanks to the effort of PowerCon Embedded, KK Wind Solutions has managed to reduce the risk in the projects and advance the time of delivery to the customer.

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It has been a pleasure to work with PowerCon Embedded. The cooperation has been seamless and efficient, and PowerCon Embedded has added value from day one. We will definitely use PowerCon Embedded again.

Henrik Lykke Christiansen

SW MANAGER, KK Wind Solutions

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Full Scale Converter for Wind Turbine

Full Scale Converter for Wind Turbine

OGIN ENERGY

The company Ogin Energy  needed a converter for its new generation of wind turbines.  The existing standard converters seemed unable to meet Ogins physical design requirements and needed significant customizations/development in order to meet Ogins technical requirements. 

In fact, Ogin asked PowerCon to design and build the new full scale converter, provided that the PowerCon engineering team was able to develop a tailor-made converter at a cost level that could compete with known standard converters – and still without compromising reliability and technical compliance.

In 2012 Ogin acquired a new generation of converters for its new series of wind turbines. The new converter was designed, developed and built by PowerCon in just 10 months.

In close collaboration with Ogin, PowerCon’s engineering teams designed, developed and built a full-scale Power system including cabinets, power-stage, filters, cooling system, converter controller and software. All 100% technically compliant and fully meting the reliability requirements.

PowerCon delivered a technical design and a solution that in addition to meeting all the technical and non-technical requirements also provides the ownership, control and flexibility that is so important in a market which constantly changes.

The fact that Ogin gained ownership to the design, made it possible to integrate the converter and the control systems into the same cabinet and place it in the nacelle – which has a major impact on the cost.

The control-platform was designed and developed by the same team that was eventually spun out to a new company under the name of PowerCon Embedded A/S.

PowerCons Engineering teams spent only 10 months and 12.000 working hours to design, develop and build a fully operational full scale converter to Ogin. 

After just 10 months, the design was pre-tested, released and a converter prototype was installed in the Ogin Wind Turbine Generator that was successfully put into operation. PowerCon had delivered according to the agreed budget and time schedule.

By investing 2 million USD in a tailor-made full scale converter, Ogin gained full control over its supply chain and acquired a solution that will reduce costs by a double-digit million USD figure per year, compared to alternative solutions based on standard converters. This is according to the original business case and provided that the projected production levels are reached.

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Full Scale Power Converter

I have never before seen such a complex project completed in such a short time and with such success.

Finn Høeg

VP, CONTROLS & ELECTRICAL, ODIN ENERGY

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