PROJECT B-TECH (PASS)

WIND TURBINE

GOVERNMENT COLLEGE OF TECHNOLOGIES

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GOVERNMENT COLLEGE OF TECHNOLOGIES DEPARTMENT OF MECHNICAL TECHNOLOGY YEAR 2010-2011 PROJECT B-TECH (PASS)

WIND TURBINE

GROUP 1. 2. 3. 4. 5. ABDUL REHMAN MUHAMAMD AHMED ALI RAZA AHMED JAFFER ZOHAIB ANSARI

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DEPARTMENT OF MECHNICAL TECHNOLOGY YEAR 2010-2011

Acknowledgement

All praise and thanks for AL-MIGHTY ALLAH who is the source knowledge and wisdom to mankind and to his beloved prophet MUHAMMAD (S.A.W.W) who show the light of knowledge to the humanity as whole

My self and my ground not owe debt gratitude and sincere thanks to our indulgent and worth

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CERTIFICATE
This is to certify that Mr. Muhammad Ahmed Ali S/O Abdul Aziz Registration no. was enrolled in bachelor of Technology(Pass) program (Mechanical) he has successfully completed his project of WIND TURBINE through the collaboration of Govt:College Of Technology (GCT).Department of Mechanical technology in partial fulfillment of requirement of B-tech (Pass).

Project In charge

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CONTENT
S.No 1 2 Particular Introduction History of Wind Energy, How Wind Turbines Work Types of Wind Turbines Where Wind Power Is Harnessed Wind and Water Power ProgramWind Energy for Hydropower Applications 8 9 10 11 12 Energy Efficiency and Renewable Energy Pg.No

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WIND TURBINE ENERGY

INTRODUCTION
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Since early recorded history, people have been harnessing the energy of the wind. In the United States in the late 19th century, settlers began using windmills to pump water for farms and ranches, and later, to generate electricity for homes and industry. Industrialism led to a gradual decline in the use of windmills. The steam engine replaced European water-pumping windmills, and in the 1930s, the Rural Electrification Administrations programs brought inexpensive electric power to most rural areas in the United States. However, industrialization also sparked the development of larger windmills, wind turbines, to generate electricity. After experiencing strong growth in the mid-1980s, the U.S. wind industry hit a plateau during the electricity restructuring period in the 1990s and then regained momentum in 1999. Industry growth has since responded positively to policy incentives. Today, the U.S. wind industry is growing rapidly, driven by sustained production tax credits (PTCs), rising concerns about climate change, and renewable portfolio standards (RPS) or goals in roughly 50% of the states. Although wind power currently provides only about 1 % of U.S. electricity needs, it is growing more rapidly than any other energy source. In 2007, over 5,000 megawatts of new wind generating capacity Were installed in the United States, second only to new natural gasfired generating capacity.

Wind power has negligible fuel costs, but a high capital cost. The estimated average cost per unit incorporates the cost of construction of the turbine and transmission facilities, borrowed funds, return to
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investors (including cost of risk), estimated annual production, and other components, averaged over the projected useful life of the equipment, which may be in excess of twenty years. Energy cost estimates are highly dependent on these assumptions so published cost figures can differ substantially. Modern wind turbines fall into two basic groups: the horizontal-axis variety (the blades circle around a horizontal axis) and the vertical-axis design (the blades circle around a vertical axis). Utility-scale turbines range in size from 100 kilowatts to as large as several megawatts. Larger turbines are grouped together into wind farms which provide bulk power to the electrical grid. Single small turbines (below 100 kilowatts) are used for homes, telecommunications dishes, or water pumping. Small turbines are sometimes used in connection with diesel generators, batteries, and photovoltaic systems. These systems are called hybrid wind systems and are typically used in remote, off-grid locations where a connection to the utility grid is not available.

A key challenge for wind energy is that electricity production depends on when winds blow rather than when consumers need power. Winds variability can create added expenses and complexity in balancing supply and demand on the grid. Recent studies imply that these integration costs do not become significant (5%-10% of wholesale prices) until wind turbines account for 1 5%-30% of the capacity in a given control area. Another concern is that new transmission infrastructure will be required to send the wind generated power to demand centers. Building new lines can be expensive and time-consuming, and there are debates

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over how construction costs should be allocated among end-users and which pricing methodologies are best. Opposition to wind power arises for environmental, aesthetic, or aviation security reasons. New public-private partnerships have been established to address more comprehensively problems with avian (bird and bat) deaths resulting from wind farms. Some stakeholders oppose the construction of wind plants for visual reasons, especially in pristine or highly-valued areas. A debate over the potential for wind turbines to interfere with aviation radar emerged in 2006, but most experts believe any possible problems are economically and technically manageable. Wind power has become mainstream in many regions of the country. Wind technology has improved significantly over the past two decades, and wind energy has become increasingly competitive with other power generation options. Federal wind power policy has centered primarily on the production tax credit (PTC), a business incentive to operate wind facilities. The PTC was extended through 2013. Analysts and wind industry representatives argue that the on-again off-again nature of the PTC is inefficient and leads to higher costs for the industry. While wind energy still depends on federal tax incentives to compete, key uncertainties like climate policy, fossil fuel prices, and technology progress could dominate future cost competitiveness.

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History of Wind Energy

Since early recorded history, people have been harnessing the energy of the wind. Wind energy propelled boats along the Nile River as early as 5000 B.C. By 200 B.C., simple windmills in China were pumping water, while vertical-axis windmills with woven reed sails were grinding grain in Persia and the Middle East Early in the twentieth century; windmills were commonly used across the Great Plains to pump water and to generate electricity. The way of using the energy of the wind eventually spread around the world. By the 11th century, people in the Middle East were using windmills extensively for food production; returning merchants and crusaders carried this idea back to Europe. The Dutch refined the windmill and adapted it for draining lakes and marshes in the Rhine River Delta. When settlers took this technology to the New World in the late 19th century, they began using windmills to pump water for farms Industrialization. However, industrialization also sparked the development of larger windmills to generate electricity. Commonly called wind turbines, these machines appeared in Denmark as early as 1890. In the 1940s the largest wind turbine of the time began operating on a Vermont hilltop known as Grandpa's Knob. This turbine, rated at 1.25 megawatts in winds of about 30 mph, fed electric power to the local utility network for several months during World War II.

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The popularity of using the energy in the wind has always fluctuated with the price of fossil fuels. When fuel prices fell after World War II, interest in wind turbines waned. But when the price of oil skyrocketed in the 1 970s, so did worldwide interest in wind turbine generators. The wind turbine technology R&D that followed the oil embargoes of the 1 970s refined old ideas and introduced new ways of converting wind energy into useful power. Many of these approaches have been demonstrated in "wind farms" or wind power plants groups of turbines that feed electricity into the utility grid in the United States and Europe. Today, the lessons learned from more than a decade of operating wind power plants, along with continuing R&D, have made wind-generated electricity very close in cost to the power from conventional utility generation in some locations. Wind energy is the world's fastest-growing energy source and will power industry, businesses and homes with clean, renewable electricity for many years to come

HOW WIND TURBINE WORKS

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How Wind Turbines Work

Wind is a form of solar energy. Winds are caused by the uneven heating of the atmosphere by the sun, the irregularities of the earth's surface, and rotation of the earth. Wind flow patterns are modified by the earth's terrain, bodies of water, and vegetation. Humans use this wind flow, or motion energy, for many purposes: sailing, flying a kite, and even generating electricity. The terms wind energy or wind power describes the process by which the wind is used to generate mechanical power or electricity. Wind turbines convert the kinetic energy in the wind into mechanical power. This mechanical power can be used for specific tasks (such as grinding grain or pumping water) or a generator can convert this mechanical power into electricity. So how do wind turbines make electricity? Simply stated, a wind turbine works the opposite of a fan. Instead of using electricity to make wind, like a fan, wind turbines use wind to make electricity. The wind turns the blades, which spin a shaft, which connects to a generator and makes electricity. Take a look inside a wind turbine to see the various parts. View the wind turbine animation to see how a wind turbine works. This aerial view of a wind power plant shows how a group of wind turbines can make electricity for the utility grid. The electricity is sent through transmission and distribution lines to homes, businesses, schools, and so on.

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TYPES OF WIND TURBINE

There are two types of wind machines (turbines) used today, based on the direction of the rotating shaft (axis): horizontalaxis wind machines and vertical-axis wind machines. The size of wind machines varies widely. Small turbines used to power a single home or business may have a capacity of less than 100 kilowatts. Some large commercial-sized turbines may have a capacity of 5 million watts, or 5 megawatts. Larger turbines are often grouped together into wind farms that provide power to the electrical grid.

Horizontal-axis Turbines Look Like Windmills

Most wind machines being used today are the horizontal-axis type. Horizontal-axis wind machines have blades like airplane propellers. A typical horizontal wind machine stands as tall as a 20-story building and has three blades that span 200 feet across. The largest wind machines in the world have blades longer than a football field. Wind machines stand tall and wide to capture more wind.

Vertical-axis Turbines Look Like Egg Beaters

Vertical-axis wind machines have blades that go from top to bottom. The most common type the Darrieus wind turbine,
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named after the French engineer Georges Darrieus who patented the design in 1931 looks like a giant, two-bladed egg beater. This typeof vertical wind machine typically stands 100 feet tall and 50 feet wide. Vertical-axis wind machines make up only a very small share of the wind machines used today. Many wind plants are not owned by public utility companies. Instead, they are owned and operated by business people who sell the electricity produced on the wind farm to electric utilities. These private companies are known as Independent Power Producers. Many wind plants are not owned by public utility companies. Instead, they are owned and operated by business people who sell the electricity produced on the wind farm to electric utilities. These private companies are known as Independent Power Producers.

Many wind plants are not owned by public utility companies. Instead, they are owned and operated by business people who sell the electricity produced on the wind farm to electric utilities. These private companies are known as Independent.In addition to emissions reductions, the increased use of wind energy will reduce water consumption. Electricity generation accounts for 50% of all water withdrawals in our nation. The 20% wind scenario is projected to result in an 8% reduction (or 4 trillion gallons) in cumulative water use by the electric sector from 2007 through 2030. In 2030, annual water consumption in the electric sector will be reduced by 17%. Meeting the Challenges
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The 20% report concluded that, although achieving 20% wind energy is technically feasible, it requires enhanced transmission infrastructure, increased U.S. manufacturing capacity, streamlined siting and permitting regimes, and improved reliability and operability Of wind systems. To address these challenges, the DOE Wind Program collaborates with federal, state, industry, and stakeholder organizations to lead wind-energy technology research, Development, and application efforts. Enhancing Wind Integration One of the challenges to meeting 20% of the nations electricity demand with wind energy is moving the electricity from the often remote areas where it is produced to the nations urban Our nation. The 20% wind scenario is projected to result in an 8% reduction (or 4 trillion gallons) in cumulative water use by the electric sector from 2007 through 2030. In 2030, annual water consumption in the electric sector will be reduced by 17%. In addition to the need for expanding and improving the nations transmission system, the natural variability of the wind resource can present challenges to grid system operators and planners with regard to managing regulation, load following, scheduling, line voltage, and reserves. Although the current level of wind penetration in the United States and around the world has provided substantial experience for successful grid operations with wind power, many grid operators are still concerned about the impacts that increasing the percentage of wind in
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their energy portfolios will have on system reliability. To increase utility understanding of integration and transmission issues associated with increased wind power generation, Wind Program researchers at the DOE national laboratories are working with industry partners on mitigating interconnection impacts, electric power market rules, operating strategies, and system planning needed for wind energy to compete without disadvantage to serve the nations energy needs. Increasing the Manufacturing Capacity and Growing a Skilled Workforce Achieving 20% wind energy would also support an expansion of the domestic manufacturing sector and related employment. To keep pace with this rapid growth, manufacturers need to develop robust and costeffective manufacturing processes that incorporate automated systems to reduce labor intens

Where Wind Power Is HarnessedTechno-Economic

Analysis of Condition MonitorinWind farm operators and academics have
only recently begun to understand the importance of wind farm operation and maintenance policy and associated operational issues. This is reflected in the papers published since 2006 which are very specifically focused on determining the value or discussing the effects of adopting certain wind farm maintenance policies. Most of these papers mention the importance of 22

quantifying the economic value of WI' CM or include models so that a CBM policy can be benchmarked against other maintenance policies. Giebhardt et al. (2007) discuss economic and technical aspects of CM in the offshore case. The authors point out that although availability for modern wind turbines is high (typically 97%), the annual frequency of failures has increased significantly as machines get larger: however this has a limited effect onshore due to relative ease of repair. Offshore conditions may have a large negative impact on WI' availability, with logistics being a major factor. Some proposed installations located 50km to shore could pose problems, which combined with less frequent maintenance and hostile offshore environment, could reduce availability to as low as 65%. This is broadly similar to observed availability of the Scroby Sands offshore wind farm (Scroby Sands, 2006) in the second year of production, particularly during winter months.

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The cost-intensive nature of offshore maintenance, due to use of specialised heavy equipment, is highlighted by the authors (Giebhardt et aL, 2007). The main traits of different maintenance policies are summarised: breakdown (reactive) maintenance is discounted because of unacceptably lengthy resultant downtimes offshore, reinforcing the assumption in this thesis that it should not be considered. Periodic maintenance is criticised for its inefficiency, since components are not used for the whole useful life, and the process is highly weather dependant. CBM is the focus of the rest of the paper: the two main challenges are use of CM information to estimate remaining life, and knowing when to trigger maintenance actions. The authors assert that more development is required particularly to improve the condition estimation algorithms, calling into question the robustness of WI' CMS and suitability to offshore deployment. However, there are no calculations underpinning the assertions of the authors, for example the impact of low reliability on offshore yield. A discussion of CM techniques follows: the main points yielded from this are a lack of empirical data, and thus limited collective experience of different failure modes (since operators are reluctant to share information). The large number of possible failure modes on the drive-train is complicated by different operational conditions which change the vibration characteristics of the drivetrain, making fault diagnosis difficult. Despite the practical difficulties highlighted by the authors, the possible scope for performing maintenance according to significance of faults would result in optiniised maintenance, which may make the CMS capital outlay worthwhile. Again, this assertion is not supported by any kind of calculation of the techno-economic benefit of WT CM.

In terms of actual quantification of WI' CM benefit, the study by Ribrant and Bertling (2007) aims to show how use of condition monitoring systems for improved planning of maintenance actions can result in more cost-optimal operation. The authors distinguish between corrective maintenance (postfailure) and preventive maintenance (pre-failure). Preventive maintenance is further broken down into scheduled and condition-based maintenance. Reliability-centred asset management (RCAM), i.e. the concept of developing RCM into a quantitative approach, is suggested as a suitable framework for 24

evaluating the impact of various maintenance policies for WTs. life-cycle cost analysis (LCCA) and present

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value (PV) calculations are used alongside this in order to quantify the economic lifetime benefit of utili7ing a CMS. Data are presented regarding maintenance policies and other operational information from two wind farms: Olsvenne 2 in Gotland, Sweden and Kentish Flats in the UK. The data presented from Vattenfall regards scheduled maintenance: minor maintenance requires 4 hours labour and needs 2 people, while major maintenance requires 7 hours and 2 people. In each case, the cost per hour for a Vestas technician is 54. Scheduled maintenance at Kentish Flats costs 750 per day per person. Unscheduled maintenance costs are 850 per day per person. The main conclusions of the paper are that a decrease in corrective (i.e. breakdown) maintenance is needed in order to justify the CMS - a highly intuitive conclusion. In terms of quantification, the authors conclude that availability would have to increase by 0.43% annually to cover the CMS costs. Alternatively, 45% of corrective maintenance needs to be 'displaced' by preventative maintenance. No further information is given regarding failure rates, downtime or availability, possibly due to the commercially sensitive nature of the data. Additionally, very little detail is given on the models used to calculate the results. This lack of transparency casts some doubt on the yielded results. Andrawus et al. (2006) had produced a paper independently of Ribrant and Bertling which used a near-identical conceptual approach, but provided much greater transparency in terms of presentation of their model. The authors compiled detailed costs and extracted sub-component failure rates from 6 years of wind turbine SCADA data, with the goal of deciding a suitable maintenance strategy. A reliability-centred maintenance exercise was conducted to identify the key operational components. Asset life-cycle analysis was used to carry out a study into the economic viability of the system. Finally, Monte Carlo simulation was employed to introduce uncertainty into key variables. little detail was given on the analytical aspects, for example the range of failure rates considered was not discussed or explicitly stated. This approach suggested that, for the conditions evaluated, a Condition Based Maintenance (CBM) strategy is the most cost-effective option. The total savings of Li 80,152 26

were discounted using net present value, and equate to an annual saving of L385 per turbine over the 18 year life cycle of a 26 turbine onshore wind farm.

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Even for the idealised case of a perfect CM system considered by Andrawus and colleagues, these savings are very small and cannot be contextualised since only one scenario of reliability level and downtime is considered. Another drawback of the approach in this paper is the fact that only two failure modes are considered (gearbox and generator failure). This is because the reliability data are taken from a single wind farm which only experienced these two failures. The research in this thesis has attempted to bridge this gap by using WI' reliability figures over large populations as opposed to individual wind farms. A further assumption made by Andrawus et al. is that the CM system can mitigate all failure modes experienced by the wind farm. This presents an idealised and hence optimistic picture of the cost-effectiveness of the CMS. This assumption is prevalent in all the economic evaluations of WT CM which have been published until now, excepting the author of this thesis. The models presented in this thesis challenge this idealistic assumption by modelling imperfect CM-based diagnosis, i.e. not all failures are caught. The same authors (Andrawus et al, 2007) outlined the principle of maintenance optimisation with application to wind turbines. The authors highlight the fact that RCM, while a useful engineering approach, is qualitative. Therefore they explore methods to obtain quantitative results in order to compare different maintenance approaches for WTs. Two methods are summarised for this purpose: modelling system failures (MSF) which resembles reliability analysis with a solution obtained via MCS rather than analytically. The second method is based on delay time maintenance model, where the 'time to next failure' is based on the Homogeneous Poisson Process model. The paper also discusses the data requirements of the approaches and gives an example of a WI' reliability block diagram, although no results are included. The strength of the approach presented by Andrawus and associates is its highly detailed RCM-style analysis of the WT system to the sub-component level, which will be specific to the type of turbine analysed. However this approach also has some ]iniitations which could dispute the validity of the conclusions reached by the authors. First of all, the lack of consideration of environmental factors such as weather conditions represents a simplification of the real case, where maintenance is subject to strict weather constraints. 28

Secondly, as metioned previously, the models assume CBM is 100% effective which is a

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