What can be done to reduce these costs?
The best answer is predictive maintenance. Supervisory Control and Data Acquisition (SCADA) systems allow operators to monitor and act upon failures or poor performance, and more advanced data collection and analysis allows maintenance tasks to be predicted.
Predictive technologies include Condition Monitoring Systems (CMS). These capture and analyse as much as 250 physical data points, including torque and force measurements, acoustic emissions, electrical strain gauges, oil particle counters and main bearing damage. Sensors capture the data, then AI or machine learning is used to improve the accuracy of the predictions and reduce false alarms as the system is embedded, and the installation base grows.
The benefits for utilising CMS are clear to see, with one monitoring system provider claiming that 90% of developing faults are detected 5 months before failure, driving 175% annual ROI from greater uptime, and reducing emergency maintenance trips by up to 50%.
Predictive maintenance drives 175% annual ROI for offshore wind farms
Further, improving quality control reduces the risk of accidents, which could then reduce insurance premiums.
A key part of this process is the transmission of the sensor data to the cloud, and from there to the client’s IT system, where the data is collected, stored and analysed.
Sensor data is often transmitted through underwater cables, which offers many benefits: it’s fast, secure, and can carry a large amount of data cost-effectively. However wired communication does have drawbacks that can be resolved by co-locating a wireless solution.
Wired vs. wireless or wired plus wireless?
If you already have a wired connection to your wind farm, it’s worth considering a wireless system to complement it, because the ease of adding new sensors to a wireless network is far greater than trying to wire in additional points into a legacy system. You simply need to place your sensors where they need to be to capture the required data, and switch them on. With no need to run cabling, you’re saving time and money, and benefitting from the additional sensor data faster.
Further, because you’re creating a dedicated wireless network for your SCADA data, its findings can be transmitted independently of other data sources. This provides both resilience in the event that your wired connection is disrupted, and allows you, if you choose, to put bespoke security measures around your OT data stream.
In addition to which, you can speed up the rate of data transmission from the industry standard of every 10 minutes, to virtually real time. In turn, this ensures that your maintenance teams get close to real-time information to help inform decisions on what issue to address, when. In fact, Turbit estimates that you can increase output by up to 5% by applying corrective measures faster.
If you were building a new offshore wind farm and decided to use only wireless connectivity to connect your assets, it can cost as little as 10% of the wired alternative, as well as being faster to implement. That said, while the cost of installation is far less, satellite and cellular connections generally come with a monthly usage fee, and they’re only suitable for relatively small amounts of data. For this reason, in our experience, most operators are exploring hybrid wired and wireless setups.
But adding a wireless network isn’t always straightforward for offshore wind farms, as they may fall outside the reach of cellular networks. 4G/LTE services typically extend to around 12 nautical miles from the coast, and wind farms can be built up to 43 miles offshore, which leaves a gap.
That gap can be bridged with a private cellular network, which offers great throughput and tight data security, but this is expensive and time consuming to set up.
