This project is cofinanced by the European Union. Sveučilište u Zagrebu Fakultet elektrotehnike i računarstva. dr.sc. Vinko Lešić

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1 This project is cofinanced by the European Union. Sveučilište u Zagrebu Fakultet elektrotehnike i računarstva dr.sc. Vinko ešić

2 Kvarovi generatora i motivacija Upravljanje otporno na kvarove generatora Utjecaj na sustav vjetroagregata Smanjenje vibracija pri upravljanju momentom generatora Zaključak CEEStructHealth radionica, V. ešić

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6 Source: J. Ribrant (Swedish wind turbines ) CEEStructHealth radionica, V. ešić

7 Gearbox concept and direct-drive Source: J. Ribrant (Swedish wind turbines ) CEEStructHealth radionica, V. ešić

8 Electric machines failure frequency in wind turbines is about 10 times greater than in industry applications harsh environment frequently varying operating conditions In industry applications: 35% of faults - stator related (e.g. insulation degradation) 30% of induction machine faults - rotor related (cage) Wind turbines are placed on hardly reachable, remote locations ots of expensive monitoring and control equipment is already installed great opportunity for diagnostics and control system interventions CEEStructHealth radionica, V. ešić

9 Cage defects (squirrel-cage induction generator) Stator insulation faults Both kinds of faults can be related with instantaneous rotor flux linkage position CEEStructHealth radionica, V. ešić

10 Cage defects (squirrel-cage induction generator) Stator insulation faults Both kinds of faults can be related with instantaneous rotor flux linkage position Faults spread rapidly in normal operation CEEStructHealth radionica, V. ešić

11 Healthy conditions Damaged rotor bar G. Stojčić et. al., Separating Inherent Asymmetries from High Sensitivity Rotor Bar Fault Indicator, SDEMPED 2011 CEEStructHealth radionica, V. ešić

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13 Cause: Intervention: Methodology: Rotor cage defect: Cyclic thermal stress, bar-end-ring connection Reduction of current flow through damaged cage part Torque modulation with frequency Stator insulation fault: Moisture, vibrations, thermal stress, PWM supply Reduction of current flow through damaged insulation part Stator flux modulation with frequency 2 sl e 2 CEEStructHealth radionica, V. ešić

14 Cause: Intervention: Methodology: Rotor cage defect: Cyclic thermal stress, bar-end-ring connection Reduction of current flow through damaged cage part Torque modulation with frequency Stator insulation fault: Moisture, vibrations, thermal stress, PWM supply Reduction of current flow through damaged insulation part Stator flux modulation with frequency 2 sl e 2 Fast loop: Modulation of torque/stator flux Slow loop: Optimal power production CEEStructHealth radionica, V. ešić

15 T T t g1 t) t g2 ( t) T2 e T g _ nonf T1 1 ( e T T 2 T gf CEEStructHealth radionica, V. ešić

16 T T t g1 t) t g2 ( t) T2 e T g _ nonf T1 1 ( e T Mean torque = optimum torque T 2 T gf CEEStructHealth radionica, V. ešić

17 WT 700 kw CEEStructHealth radionica, V. ešić

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19 Cage defect simulated at t=50 s owered rated speed CEEStructHealth radionica, V. ešić

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21 Control cabinet dspace 1103 ControlDesk software CEEStructHealth radionica, V. ešić

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25 short circuit CEEStructHealth radionica, V. ešić

26 i k short circuit CEEStructHealth radionica, V. ešić

27 i k short circuit i k ( t) 1 Z k d sx ( t) dt CEEStructHealth radionica, V. ešić

28 i k short circuit i k ( t) 1 Z k d sx ( t) dt d sx( t) dt K FTC CEEStructHealth radionica, V. ešić

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30 Healthy insulation J. Yang et. al., An advanced stator winding insulation quality assessment technique for inverter-fed machines, TIA i leak ( t) C dusx( t) dt CEEStructHealth radionica, V. ešić

31 Healthy insulation J. Yang et. al., An advanced stator winding insulation quality assessment technique for inverter-fed machines, TIA i leak ( t) C dusx( t) dt Degraded insulation i leak ( t) 1 R u sx ( t) 1 R d sx( t) dt CEEStructHealth radionica, V. ešić

32 Healthy insulation J. Yang et. al., An advanced stator winding insulation quality assessment technique for inverter-fed machines, TIA i leak ( t) C dusx( t) dt Degraded insulation i leak ( t) 1 R u sx ( t) 1 R d sx( t) dt d sx( t) dt K FTC CEEStructHealth radionica, V. ešić

33 Generally: sx ( t) s sin t e x d sx( t) dt s cos e t e x CEEStructHealth radionica, V. ešić

34 s Option A reduction of such that s e is kept below the imposed limit CEEStructHealth radionica, V. ešić

35 Option B modulation of stator flux magnitude (t) such that the imposed restriction is matched s d sx( t) dt K FTC CEEStructHealth radionica, V. ešić

36 Triangular waveform of stator flux is achieved with FOC and current control loops: sx ( t) K FTC e et x sin( t ) e x ( t) sx K FTC x t e CEEStructHealth radionica, V. ešić

37 Triangular waveform of stator flux is achieved with FOC and current control loops: sx ( t) K FTC e et x sin( t ) e x ( t) sx K FTC x t e sd sq l l i i sd sq m r rd rd sl konst. sln CEEStructHealth radionica, V. ešić

38 Periodic strengthening and weakening of machine flux in the air gap CEEStructHealth radionica, V. ešić

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43 T g 3 2 p pmi 3 sq T g p pm sd sq i sd i sq 2 CEEStructHealth radionica, V. ešić

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46 i i sd * sd ( s) ( s) rd( s) i ( s ) sd f J 1 1 s 1 T m r s x k 1 y Ax Bu C k k x k Cost function: - (t) sd tracks reference 2 0 k i sd x * u i sd * T * T C X R Q C X R U HU fu g minimise J H B * T C Time-critical: * T * * QC B T * T * T T * * x A C R QC B T s sd * ( t) 200s U y H f sd T rd On-line control law: i l sd m r rd CEEStructHealth radionica, V. ešić

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50 Rotor cage defect fault-tolerant control CEEStructHealth radionica, V. ešić

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52 Blade root Blade root Tower tip CEEStructHealth radionica, V. ešić

53 Blade root Blade root Tower tip CEEStructHealth radionica, V. ešić

54 Stator insulation fault-tolerant control CEEStructHealth radionica, V. ešić

55 generator generator side grid side grid simplorer Field-oriented control Voltage-oriented control Fault-tolerant control matlab CEEStructHealth radionica, V. ešić

56 THD increase from 2.51% to 2.95% CEEStructHealth radionica, V. ešić

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58 l offset l, t offset mod e j2 CEEStructHealth radionica, V. ešić

59 ocation l offset l, t offset mod e j2 Value CEEStructHealth radionica, V. ešić

60 ocation l offset l, t offset mod e j2 dq model: ld offset lq mod mod sin( 2 ) cos( 2 ) Value CEEStructHealth radionica, V. ešić

61 ocation l offset l, t offset mod e j2 dq model: ld offset lq mod mod sin( 2 ) cos( 2 ) Value mod offset CEEStructHealth radionica, V. ešić

62 ld l mod, e mod, r cos( 2 ) cos( 2 ) r e mod, s mod, b cos(2 ) s cos(2 ) b e s e N s e lq mod, e sin( 2 ) e mod, s sin( 2 ) s r sl mod, r sin( 2 ) r mod, b sin( 2 ) b b N b sl Stator anisotropy: Saturation saliency Slots anisotropy Rotor anisotropy: Cage defects Bars anisotropy CEEStructHealth radionica, V. ešić

63 Model u u sd sq u u sd sq k a i R i s sd sq a a di dt di sd sq dt k a R s a T r s Conventional model u u sd sq s T e r a i mr e a i sq s a i mr eaisd a l CEEStructHealth radionica, V. ešić

64 CEEStructHealth radionica, V. ešić 49 Model dt di i k u u sd a sd a sd sd dt di R i u u sq a sq s sq sq r s a s a T R k mr s ld lq e r a s sq a e s ld lq sq ld lq sd i T i R u u mr a s e r s ld lq sd a e r s ld lq s ld lq sd ld lq sd i T i T R u u Anisotropic model ld lq ld a 2

65 Estimation turned on at t=10 s CEEStructHealth radionica, V. ešić

66 Cyclic stress on the shaft causes material fatigue Mife toolbox, developed by NRE Constant load Dynamical load 66% reduction 59% reduction CEEStructHealth radionica, V. ešić

67 Considered generator faults can be suppressed by proper manipulation of variables that cause rapid fault spreading The sooner the fault is detected, the more power is extracted with proposed methods Methods offer additional reliability centered maintenance possibilities Broad application in electrical drives CEEStructHealth radionica, V. ešić

68 Projekte CEEStructHealth i Will4Wind sufinancira Europska unija kroz Europski fond za regionalni razvoj. Dodatne informacije: Sadržaj ovog izlaganja isključiva je odgovornost autora i ona ne odražava nužno mišljenje Europske unije. CEEStructHealth radionica, V. ešić

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70 Sinusoidal current vs squared voltage increases iron losses by about 40% Increase in 3 rd harmonic CEEStructHealth radionica, V. ešić

71 Wind farm Installed power (MW) Region Annual production (GWh) Wind turbine models Put in operation VE Danilo 43 Šibensko-kninska županija Enercon E MW VE Vrataruša 42 ičko-senjska županija Vestas V90-3 MW VE Kamensko-Voštane 40 Splitsko-dalmatinska županija Siemens SWT MW VE Bruška (ZD2+ZD3) 36 Zadarska županija Siemens SWT-93-2,3 MW VE Ponikve 34 VE Jelinak 30 VE Pometeno Brdo 17.5 Dubrovačko-neretvanska županija Splitsko-dalmatinska županija Splitsko-dalmatinska županija x Enercon E-70 2,3 MW x Acciona AW ,5 MW Končar KO-VA 57/1 1 MW +1 Končar VA K80 2,5 MW VE Trtar-Krtolin 11.2 Šibensko-kninska županija Enercon E-48-0,8 MW VE Crno Brdo 10 Šibensko-kninska županija 27 7 eitwind TW77 1,5 MW VE Orlice 9.6 Šibensko-kninska županija Enercon (3 x E-48 0,8 MW + 8 E-44 0,9 MW) VE ZD 4 faza I 9.2 Zadarska županija 26 4 Siemens SWT 93 2,3 MW VE Velika Popina (ZD6) 9 Zadarska županija 26 4 Siemens SWT 93 2,3 MW VE Ravne 5.95 Zadarska županija 15 7 Vestas V52 0,85 MW Total MW DFIG WRSG SCIG PMSG CEEStructHealth radionica, V. ešić

72 J * T * T C X R Q C X R U HU fu g U H f T CEEStructHealth radionica, V. ešić

73 i d I cos I cos cos2t I sin sin 2t DC component AC component R. Teodorescu, M. iserre, P. Rodriguez, Grid converters for photovoltaic and wind power systems CEEStructHealth radionica, V. ešić