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Wind Turbine Reliability Database Update SANDIA REPORT SAND2009-1171 Unlimited Release Printed March 2009 Wind Turbine Reliability Database Update Roger R. Hill, Valerie A. Peters, Jennifer A. Stinebaugh and Paul S. Veers Prepared by Sandia National Laboratories Albuquerque, New Mexico 87185 and Livermore, California 94550 Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy’s National Nuclear Security Administration under Contract DE-AC04-94AL85000. Approved for public release; further dissemination unlimited. Issued by Sandia National Laboratories, operated for the United States Department of Energy by Sandia Corporation. NOTICE: This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government, nor any agency thereof, nor any of their employees, nor any of their contractors, subcontractors, or their employees, make any warranty, express or implied, or assume any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represent that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government, any agency thereof, or any of their contractors or subcontractors. The views and opinions expressed herein do not necessarily state or reflect those of the United States Government, any agency thereof, or any of their contractors. Printed in the United States of America. This report has been reproduced directly from the best available copy. Available to DOE and DOE contractors from U.S. Department of Energy Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831 Telephone: (865) 576-8401 Facsimile: (865) 576-5728 E-Mail: [email protected] Online ordering: http://www.osti.gov/bridge Available to the public from U.S. Department of Commerce National Technical Information Service 5285 Port Royal Rd. Springfield, VA 22161 Telephone: (800) 553-6847 Facsimile: (703) 605-6900 E-Mail: [email protected] Online order: http://www.ntis.gov/help/ordermethods.asp?loc=7-4-0#online 2 SAND2009-1171 Unlimited Release Printed March 2009 Wind Turbine Reliability Database Update Roger R. Hill, Valerie A. Peters, Jennifer A. Stinebaugh, and Paul S. Veers Wind Energy Technology Department Sandia National Laboratories P.O. Box 5800 Albuquerque, NM 87185-1124 Abstract This report documents the status of the Sandia National Laboratories' Wind Plant Reliability Database. Included in this report are updates on the form and contents of the Database, which stems from a five- step process of data partnerships, data definition and transfer, data formatting and normalization, analysis, and reporting. Selected observations are also reported. 3 4 Contents INTRODUCTION ..................................................................................................................................................................... 7 OBJECTIVES OF THE WIND PLANT RELIABILITY DATABASE AND ANALYSIS PROGRAM ........................... 8 PROGRAM ACTIVITIES FROM INCEPTION THROUGH FY08 ................................................................................... 8 THE NATIONAL RELIABILITY DATABASE .................................................................................................................... 9 DATA PARTNERSHIPS .......................................................................................................................................................... 9 DATA DEFINITION AND TRANSFER ............................................................................................................................... 10 SCADA DATA ....................................................................................................................................................................... 10 WORK ORDER DATA .............................................................................................................................................................. 11 SUMMARIZED DATA .............................................................................................................................................................. 11 DATA CHALLENGES ............................................................................................................................................................... 12 DATA FORMATTING AND NORMALIZATION ............................................................................................................. 12 ANALYSIS PROCESS ............................................................................................................................................................ 13 REPORTING AND ANALYSIS OUTPUT ........................................................................................................................... 14 PARTNER REPORT - SAMPLE .................................................................................................................................................. 14 SUMMARY STATISTICS ........................................................................................................................................................... 15 APPENDIX A – TAXONOMY ............................................................................................................................................... 19 TAXONOMY (TOP 2 LEVELS)................................................................................................................................................... 25 APPENDIX B – REPORT TEMPLATE FOR INDIVIDUALIZED REPORTS TO PARTNERS .................................. 26 APPENDIX C: PRO-OPTA ................................................................................................................................................... 27 IMPORT SETUP ....................................................................................................................................................................... 27 DATA ANALYZER .................................................................................................................................................................. 27 DATA MANAGER ................................................................................................................................................................... 27 FAULT TREE INTERFACE ........................................................................................................................................................ 28 RESULTS MODULE ................................................................................................................................................................. 28 OPTIMIZER ............................................................................................................................................................................. 28 APPENDIX D: BLADE RELIABILITY SURVEY ............................................................................................................. 29 5 Figures FIGURE 1: TURBINE TIME ALLOCATION PIE CHART ................................................................................................................... 16 FIGURE 2: AVAILABILITY AND UTILIZATION TRENDS ................................................................................................................. 17 FIGURE 3: COST PERFORMANCE DRIVERS .................................................................................................................................. 17 FIGURE 4: COST HIGH VARIABILITY DRIVERS ............................................................................................................................ 18 Tables TABLE 1: SUMMARY STATISTICS – PLANT VS. NATIONAL .......................................................................................................... 15 TABLE 2: TURBINE SUMMARY STATISTICS ................................................................................................................................. 18 6 Introduction The goal of Sandia’s Wind Plant Reliability Database and Analysis Program is to characterize the reliability performance of the US fleet to serve as a basis for improved reliability and increased availability of turbines. The Wind Plant Reliability Database and Analysis Program is designed to fill a need identified by wind plant owners and operators to better understand wind turbine component failures so efforts can be focused to resolve these failures and /or mitigate the consequences, resulting in improved operations and reduced maintenance costs. With sufficient participation across the fleet, benchmarking of fleet-wide reliability performance will characterize the industry as a whole. Characterization of reliability issues will help prioritize and facilitate R&D efforts to foster component and system design improvements. Together these actions are aimed at reducing financial and technical risks for a growing wind energy market. Sandia has historically been engaged in system reliability research activities in safety, materials, and fatigue. The broad-based expertise and capabilities that evolved from this engineering of numerous critical systems is now being applied to wind energy systems. For example, wind turbines
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