TECNALIA’s Commitment to Wind Energy TECNALIA’S COMMITMENT TO WIND ENERGY
TECNALIA I INSPIRING BUSINESS
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TECNALIA Research & Innovation is the first privately funded applied research centre in Spain and one of the leading such centres in Europe. A combination of technology, tenacity, efficiency, courage and imagination.
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TECNALIA’S COMMITMENT TO WIND ENERGY
At TECNALIA we are organised in 7 fully interconnected Business Divisions. Cooperation works thanks to the transversality of teams, projects and clients collaborating with each other, combining expertise and commitment. Our best asset is our team, made up of more than 1,500 experts who work to transform knowledge into GDP in order to improve people's quality of life by generating business opportunities for companies. We are committed to the future, society, our planet and our environment. This responsibility provides focus to our values and reinforces our activities.
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TECNALIA I INSPIRING BUSINESS
“TECNALIA transforms Knowledge into GDP to improve people's quality of life by generating business opportunities for Companies"
DOCUMENT PUBLISHED IN MARCH 2014
ONE HUNDRED AND TEN
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FIRST SPANISH PRIVATE ORGANISATION IN FINANCIAL RETURN, PROJECTS APPROVED AND LED WITHIN THE EC 7FP
EXPERTS ON STAFF
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WORKING TOWARDS A COMMON GOAL:
TO GENERATE BUSINESS OPPORTUNITIES THROUGH APPLIED RESEARCH.
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YOUR PROJECT R&D PROJECTS
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TECHNOLOGY AND INNOVATION STRATEGY
TECNALIA’s Commitment to Wind Energy TECNALIA is an applied research and technology service centre with extensive technological competences and services related to the wind energy sector in fields such as electrical power, manufacturing processes, control algorithms, advanced sensors, remote control and new materials. Cost Saving Energy
Energy for a Commitment
The aim of TECNALIA in the wind energy sector is to offer solutions and services to different sectorial players, such as project developers, industry, government, local authorities and associations. The primary objectives here are reducing energy costs for wind turbine manufacturers, operators and above all, integration in the power supply system. In synthesis, our final aim is to generate and develop business opportunities through applied research and technological services, improving efficiency and competitiveness of the whole sector, which is constantly evolving.
Moreover, TECNALIA maintains a firm commitment to the wind energy sector, collaborating with its main stakeholders throughout the value chain. Nowadays, TECNALIA is one of the most significant agents in the promotion of the offshore wind sector as an early and strategic regional project in the Basque Country. This region has also played a very important role in the technological and industrial development of the on-shore wind energy sector at a national level as well as projecting Spain as a worldwide leading market.
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Wind Farm Planning and Design
Off-Shore Wind Foundation Design
TECNALIA’S COMMITMENT TO WIND ENERGY
TECNALIA I INSPIRING BUSINESS
“Our final aim is to generate and develop business opportunities through applied research and technological services, improving efficiency and competitiveness of the whole sector, which is constantly evolving.”
Innovation for a Sector in a Continuous Evolution Offshore wind energy is more costly due to higher investment and installation costs, more expensive electrical cabling and higher operating and maintenance costs. To cope with different challenges, TECNALIA has played an active role in offshore wind farm development from the outset. This includes wind resource assessments, grid integration studies, due diligence, measuring and evaluation programs and offshore wind farm development. In conjunction with key industry players, we have commenced the development of a common design concept for floating wind turbine technology and solutions for High Power Electronic necessities, among other innovations.
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High-Power Electronics and Electrical Machines
Materials and Manufacturing
Operation & Maintenance
Wind Farm Planning and Design
Site selection for energy wind farms is crucial to assure cost efficiency and to avoid negative impacts along its subsequent life cycle. Wind resource characterisation, energy evacuation and distribution, energy power estimations, potential environmental, economic and social impacts prediction are key issues for decision-making and alternative selection for on-shore, off-shore and also urban wind farms planning and design.
WIND RESOURCE FORECASTING AND ASSESSMENT
WIND FARMS, ENVIRONMENTAL, SOCIAL AND ECONOMIC IMPACT ASSESSMENT
Weather forecasting both for energy generation estimation and for operation planning (facing extreme events episodes, for instance).
An integral approach to avoid future problems and to optimize the development considering its whole life cycle.
• High resolution numerical weather prediction for the wind industry: on-land, offshore and urban environments.
• Territorial carrying capacity for the optimal location of wind farms.
• Operational wind resource and power forecasting: on-land, offshore and urban environments. • Short-, medium- and long-term weather forecasting focused on wind industry operation. • Now-casting and extreme events forecasts, which is relevant for wind industry operation, including offshore activities. • Wind resource mapping (high resolution numerical models and geostatisical techniques). • Wind data management.
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• Planning support for energy sustainability at local and regional levels. • Environmental impact assessment: on-shore, off-shore, urban environments. • Wind farm-related social perception and social cost-benefit analysis. • Product and process life cycle assessment. • Product and process eco-design for environmental impact minimisation.
TECNALIA’S COMMITMENT TO WIND ENERGY
TECNALIA I INSPIRING BUSINESS
Wind Farm Planning and Design
Software for the Optimal Place Calculation for WIND-farms. SOPCAWIND SOPCAWIND aims at developing a new service achieved through the development of a software tool for optimal wind farm design based on a large and heterogeneous set of digitalized data containing information from different fields (wind climate, geography, environment, archaeology and socialeconomy), that will be treated, validated, standardized and converted for this extent. Two main services are being developed in the project: The Sopcawind Data Pool for consulting any data stored in the system and The Sopcawind Tool for wind farm optimization. Sopcawind involves the following partners: UPV-EHU, TECNALIA, Eurohelp, 3E, Anemos, GeoX.
Promotion and Development of Renewable Energies in Alava. Strategy and Action Plan. MUGARRI PLAN TECNALIA has supported the MUGARRI Strategy and Action Plan through the evaluation and diagnosis of the potential of the different areas in the province of Alava to promote renewable energy facilities. Moreover, it has led the strategic reflection to take profit from emerging opportunities, in order to get social, environmental and economic benefits.
• Wind resource and weather forecasting on-shore, off-shore and in urban environments. • Wind data management. • Support for optimal wind farm location considering negative and positive environmental, social and economic impacts. • Wind energy-related products and process eco-design.
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Off-Shore Wind Foundation Design
Wind turbines go to sea. The exploitation of this clean and abundant energy resource located near of large demand areas is now a reality. Off-shore wind energy further development relies on moving wind platforms to deeper waters where higher wind probability and velocity increase wind turbine efficiency. Floating wind turbines with no complex mooring systems will assure not expensive operations that consequently encourage cost-effective off-shore wind energy generation.
FLOATING OFF-SHORE WIND COMPONENTS DESIGN
Structure design for floating offshore wind power, bearing in mind the technical, economic, environmental and logistical factors as well as all the stages in wind farm development. • Conceptual design of floating platforms. • Mooring systems and umbilical cables. • Hydrodynamic analysis and naval engineering. • Cost analysis. • Life cycle analysis.
• Optimised design based on the definition of load cases for a given location. • Development of specific codes for floating off-shore wind foundation. • Aerodynamic-hydrodynamic coupling for floating off-shore wind design. • Logistics analysis from the early stages of the design.
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TECNALIA’S COMMITMENT TO WIND ENERGY
TECNALIA I INSPIRING BUSINESS
Off-Shore Foundation Design
NAUTILUS FLOATING SOLUTIONS An off-shore deep water industrial and technological consortium. NAUTILUS FLOATING SOLUTIONS SL, is an industrial and technological consortium made up of ASTILLEROS DE MURUETA, TAMOIN, VELATIA and VICINAY MARINE INNOVATION, four leading companies in advanced technology with presence in international markets, and the applied Research Centre, TECNALIA; for the development of floating platforms for the off-shore wind power market. Floating solutions are emerging as the main contenders of the future in offshore wind power generation as they respond to the need to move platforms into deeper waters where wind power is more abundant and constant and the visual impact is less, hence allowing for more powerful wind turbines. Therefore, NAUTILUS has developed a semi-submerged floating platform, which can be used in locations where the depth of the seabed does not allow for existing grounded solutions. Semi-submerged floating platforms are ideal for depths in excess of 60 meters (of which there are many areas around the world).
The advantages of the designed structure are based on its design, which allows for manufacturing in conventional shipyards, assembly of the wind turbine in port and towing and installation using conventional boats.
NAUTILUS concept will the tested at full scale in 2016. The commercial units production will start in 2016, which will have a relevant impact in local industry by providing 100 new jobs during the first 5 years of operation.
Furthermore, the current design of NAUTILUS allows 5 MW wind turbines to be hosted, but the objective is to reach up to 10 MW.
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High-Power Electronics and Electrical Machines for Wind Energy Wind turbines mechanisms, electrical substations, energy conversion and evacuation means, and so on, have to be modified to make them more cost-effective and adapted to the new emerging opportunities for wind energy. Within the framework of offshore wind energy, for instance, electric systems have to generate higher power than terrestrial / conventional wind turbines in order to develop new solutions that provide better power scalability, weight reduction and reliability with the systems involved.
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HIGH-POWER ELECTRONICS AND ELECTRICAL MACHINES
ELECTRICAL LABORATORY
Solutions for High-Power Electronic requirements, wind generator scalability and underwater electrical connectivity.
Testing of electrical components and equipment installed in wind farms and wind turbines:
• Grid layout and converters.
• Power, HV & LV Laboratories, with more than 20 years experience, under ENAC/ ILAC Accreditation.
• High Power & HVDC. • Superconductor and electrical generators. • Submarine electrical interconnection devices.
• Mobile laboratories including a Resonant Test Unit rated 260 kV, 80A. • Failure analysis of electrical components and equipment.
• High power converter design and/or tests. • Algorithms for HVDC solutions. • Laboratory tests for conformity • Design of electrical machines. assessment of electrical products and equipment (Transformers, MV & • Application of superconductivity to LV Switchgear, Boards…). electrical machines. • Design of new concepts to reduce costs • On-site tests on substations (power in the connections and interconnections transformers) and evacuation lines (HV Cables). of umbilical cables.
TECNALIA’S COMMITMENT TO WIND ENERGY
TECNALIA I INSPIRING BUSINESS
High-Power Electronics and Electrical Machines for Wind Energy
Reliable, light and powerful offshore compact electric generator based on superconducting technology. SUPERTURBINES These SUPERTURBINES reduce wind turbines weight and size by 30% while maintaining their efficiency; they can also generate10 MW or higher power while maintaining the size. These issues result in a significant cost reduction as regards the commissioning both in fixed and floating applications, and concerning the operational and maintenance work. A demonstration of the SUPERTURBINES concept is under development jointly with ACCIONA Wind Power, Acciona Energía, Columbus Superconductors, Oerlikon-Leybold Vacuum, Institute of Electrical Engineering Slovak Academic of Sciences, University of Southampton, Karlsruher Institut Technologie and D2M Engineering.
Marine environment umbilical wire - floating platform fast connection device and method. KONEKTA2 KONEKTA2 has an innovative design that allows the use of standard terminals as onshore application terminals significantly reducing the cost. Additionally, KONEKTA2 permits fast and easy connection and disconnection not requiring submerged vehicles, big ships for support or any additional element that usually makes these manoeuvres very expensive. For instance, KONEKTA2 allows fast and easy disconnection in order to tow floating wind platforms to harbour for emergencies.
New Experimental Infrastructure for Smart Grids. INGRID INGRID is a singular internationallevel laboratory, with a great experimental capacity in high-voltage and high-power. It focuses on testing equipment and components, smart grids, electrical systems for renewable energy and smart management of electrical power consumption. INGRID is able to conduct short-circuit and high power tests (up to 200 kA), power electronic devices and high and low voltage device compliance, as well as commissioning and failure assessment for high voltage equipment. A living and tailored infrastructure that is closely in contact with the industry and the global scientific community, providing support for applied research and technological development of companies.
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Materials & Manufacturing
New business opportunities are also emerging in the wind industry to improve the efficiency and costeffectiveness of components through weight reduction and materials saving. As regards cost reduction, there are significant technological breakthroughs for corrosion, bio-fouling, erosion, abrasion and frost protection which help to extend the service life of components and materials. The treatment of the materials in the production processes of large parts, such as wind turbines, has a significant room for improvement in terms of costs, precision and flexibility. Similarly, this applies to the automation of the different manufacturing processes.
METALLIC & COMPOSITE MATERIALS
Structural materials, coatings and processing: • Advanced structure materials, components and processes (i.e. composites, cast components,..). • Surface technology for corrosion, bio-fouling, erosion, abrasion, and frost protection. • Material degradation testing and failure analysis (laboratory accelerated ageing test; real exposition sites: marine environment and atmospheric condition; assessment, characterization and degradation mechanism study). • Real-time corrosion monitoring (at full remote system): information about the environmental corrosivity and the integrity of the structure as well as the passive corrosion protection system (coating).
Characterisation and evaluation of materials & components at lab-scale and real environments: • Materials characterisation in mechanical tests, chemical analysis, materialography and corrosion. • Special tests: components and assembly, extensometry, residual stresses, metallographic replication. • Assessment and diagnosis: evaluation of results and diagnosis of causes of non-compliance, review and definition of specifications. • Advice on Materials Selection and Manufacturing Processes (extensive knowledge of welding processes). • Failure Analyses, Behaviour in Service and Residual Life.
MANUFACTURING SYSTEMS
Meeting different wind industry, manufacturing processes requirements: 12
MATERIALS LABORATORY
• Optimization of conventional forging processes for gears and rotor parts. • Design of ring rolling processes for manufacturing of steel and Ni-alloys discs and rings. • Automated welding supervision and control system. • Fully automated manufacturing in dry 3D complex pre-forms.
• Control of moulding, curing and infusion processes. • Out of autoclave/liquid moulding process optimization and simulation. • Development of efficient heating tooling based on self heated mould and membranes. • Robotic, manufacturing cell design aimed at secondary processes automation (drilling, machining, inserts installation, trimming, etc.). • New machine concepts and smart and flexible tooling development. Innovative handling and assembly systems of large parts.
TECNALIA’S COMMITMENT TO WIND ENERGY
TECNALIA I INSPIRING BUSINESS
Materials & Manufacturing
Corrosion monitoring system for aggressive environments. MONICOR
CURE MONITORING SOFTWARE FOR COMPOSITES PRODUCTION PROCESSES
MONICOR, based on electrochemical impedance spectroscopy, provides a modular and remotely operated device to follow material degradation and forecast the structure maintenance in aggressive environments such as marine climatic conditions. This will reduce at maximum human in-situ intervention minimizing maintenance cost of e.g. offshore. The advantage of using a modular system is that depending on the environment and the failure process the choice of captor can be selected. This will allow to have a selective monitoring covering a wide range of applications.
TECNALIA has developed a new cure monitoring software. This application has alarms on the key points of the cure production process (point minimum viscosity, gelation, end of cure) and it is customizable according to client process requirements. This software permits to optimize the production process, reducing the cycle times, cost and energy consumption and identifying unexpected events like early gelation. It also contributes to decrease VOC through resin state control, improving knowledge of production process parameters in general.
To stand out its applications as follows: liquid moulding process (RTM, infusion...), prepregs and adhesives.
• Extended component life against wear, erosion, corrosion, increase fatigue strength using advanced materials and surface technology. • Weight saving and/or Material saving: integrated structures or components and structural optimisation, net shape pre-forms. • Pre-forming process industrialisation. • Low energy consumption during manufacturing processes. • Short overall production cycle time, from several hours to minutes. • Laboratories with an extensive range of testing facilities and accreditations under ISO 17025 concerning UNE-EN, ASTM, ISO, NACE and DIN standards and internal procedures.
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Operation & Maintenance
Proper operation and good maintenance of wind farms are keys to achieving optimal economic results by maximising the performance and extending the useful life of wind turbines. These fundamental aspects are important for wind farm operators in terms of wind business knowledge and its broad technical capabilities.
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Operational data can be leveraged via smart dataprocessing algorithms to perform fault diagnosis/ prognosis and to assess the performance of a wind turbine or a whole park. A key point is to develop smart software that puts Key Performance Indicators (KPIs), energy generation and availability statistics, forecasts and other invalueable information in an easily accessible position. Seamless integration with the monitoring system, extensibility and state-of-theart algorithms become strategic challenges for the wind sector.
CONDITION AND STRUCTURAL HEALTH MONITORING
DIAGNOSIS AND PERFORMANCE ASSESSMENT
In order to facilitate the operation and good maintenance tasks, wind promoters analyse the global performance of wind farms by conducting the following studies:
Maintenance of wind farms, reporting to various agencies, energy generation statistics and availability, same billing wind farms, or sending daily forecast.
• Instrumentation for vibration measurement, thermal and corrosion behaviour.
Schedule generation facilities to be sold in the electricity market, as follows:
• Embedded devices and distributed data acquisition. • Non-destructive testing and nonintrusive sensors. • ROV-based submarine inspection. • Development of artificial intelligencebased software tools for decision- making support.
• Estimation of real asset’s health and remaining useful life. • Maintenance strategies based on real asset`s health condition. • Risk Analysis. • Optimal inspection and corrective operation planning.
CONTROL AND COMMUNICATIONS OPTIMIZING
Reducing cost and wining security in communication of wind systems through: • High performance at low cost in the communication between the fiber ring of the wind farm and the substation.
• Optimizing main and redundant communications systems among the network elements (plants, substations and delegations). • Resilient and robust architectures in electrical and wind farms domains in terms of security.
TECNALIA’S COMMITMENT TO WIND ENERGY
TECNALIA I INSPIRING BUSINESS
Operation & Maintenance
EQUIPMENT FOR VALIDATION OF ASSETS AND PROCESSES In order to support technologists and wind farm operators during the validation of assets and due diligence processes, TECNALIA takes part in monitoring and conformity assessment campaigns by providing know-how and experience in the wind power field. To do so, it has the necessary human team together with their own specific instrumentation, communication and analysis tools.
DATA ACQUISITION SYSTEMS The first step towards smart maintenance and operation analysis involves data collection from the wind turbine. TECNALIA has broad expertise in developing on-board systems for data acquisition, characterised by their high flexibility (both HW and SW), robustness, fault-tolerance and low installation and maintenance costs. These features have made our flagship product RACING BRAVO the obvious choice for key players such as GAMESA, IBERDROLA, ACCIONA, etc.
ADVANCED DATA PROCESSING SOFTWARE PLATFORM Data gathered by the monitoring system can provide valuable insights into the operational status and condition of the system, but only if it is accessible in a convenient form and adequately processed. TECNALIA’s smart analysis software platform PRONOS provides flexible, advanced visual analysis and decision support capabilities. The platform can be extended with our own AI algorithms for fault diagnosis and prognosis or any other algorithm specially designed by our expert team.
• Development of specific on-board • Development of software tools for risk systems. analysis. • Fibre optics and unattended ultrasonics • Software tools for wind turbine for structural health. performance assessment. • Remote condition monitoring. • Remote diagnosis and prognosis of failure modes based on SCADA data • Development of software tools for via software-as-a-service. decision-making support based on artificial intelligence systems with • Automatic maintenance plan reduced human intervention. optimisation based on condition, costs and constraints analysis. • Novel corrosion sensors.
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TECNALIA Parque Científico y Tecnológico de Bizkaia C/ Geldo, Edificio 700 E-48160 Derio-Bizkaia (Spain) T 902 760 000* T+34 946 430 850 (International calls) www.tecnalia.com IGONE UGALDE Wind Energy Market. Business Development igone.ugalde@tecnalia.com TECNALIA’S COMMITMENT TO WIND ENERGY