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T I F O RGY R T RE D ENE

IN W R FO


YOUR EXPERIENCED PARTNER IN WIND Trust is the key

Bachmann electronic is the world leader in wind turbine automation. Besides future-proof technologies, high availability and quality from a single source, there‘s one thing we offer our customers above all: extensive experience and unique expertise in meeting challenging market and customer requirements worldwide with tailored solutions.

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MORE THAN: 100.000

9.000

250

50

WIND TURBINES AUTOMATED WORLDWIDE

AUTOMATION PARTNERS TRUST BACHMANN

CONDITION MONITORING SYSTEMS INSTALLED

YEARS OF AUTOMATION EXPERIENCE

BACHMANN MEANS: COMPLETE SYSTEMS & SOLUTIONS FOR WIND ENERGY. RELIABILITY, AVAILABILITY, COMPETENCE & LONG-TERM PARTNERSHIP INCLUDED.

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THINKING OF RETROFIT?

?

NEW / EXTENDED REQUIREMENTS / DEMANDS

AVAILABILITY OF COMPONENTS? SECURITY – NERC APPROVED? DATA ACCESS? LONG-TERM DATA HISTORY? DATA TRANSPARENCY? GRID COMPLIANCE? IEC STANDARDS? ACCESS CONTROL? DIAGNOSTICS/SERVICABILITY? ...

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THINK BACHMANN! We understand the big picture and always think ahead for you. Our innovative solutions ensure efficient engineering of your plants. This is what intelligent automation of state-of-the-art wind turbines looks like.

!

FULL WIND FARM TRANSPARENCY WITH WIND ENERGY 5.O SOLUTIONS

SMART TURBINE AUTOMATION Reliable, flexible and modular in hardware & software Long-term security for your turbine investment Data protection: integrated security functions

WIND SCADA SOLUTION Wind Power SCADA according IEC 61400-25 Scalable from the turbine to the wind farm

Objectives of Bachmann Retrofit ƒƒ Increase the lifespan of plants ƒƒ Increase production level

Standard communication via OPC UA

ƒƒ Increase product quality (Grid Monitoring and Protection – GMP)

GRID MANAGEMENT

ƒƒ Increased plant efficiency, e.g. through new technologies, CMS

Open, real-time communication Standards according to IEC, DNP3, Modbus OPC UA to SCADA and operational control

CONDITION MONITORING

ƒƒ Meeting legal requirements (e.g. grid monitoring, voltage control, work safety) ƒƒ Ensuring the supply of spare parts ƒƒ Update to the latest technology and grid compliance

RM Center: analysis, monitoring, reporting and consulting WebLog Expert – Advanced Monitoring Software CMS plug-ins: Unbalance Calculator, Blade Sensor and Structure Health Monitoring

DIAGNOSTIC & MAINTENANCE Diagnostic toolbox (M1 Service Center) Configurable software modules Event system and statistical evaluation Open source for individual adaptions

Benefits of Bachmann Retrofit ƒƒ Lower investment versus full replacement or repower ƒƒ No or reduced official approval processes ƒƒ Use of an existing plant ƒƒ Lower training cost as the solution adapts to the existing turbine

Web-based visualization 5


SYSTEMATIC BACHMANN CONCEPT Your wind turbines at the forefront of the technology

Professional analysis Professional analysis and assetment: and assetment: evaluate customer needs evaluate customer needs and existing assets. and existing assets.

ANALYSIS & CONCEPT ANALYSIS & CONCEPT

Customizing hardware Customizing hardware and software solutionand software solution due to requirement. due to requirement. Determent solution based Determent solution based on product portfolio. on product portfolio.

IMPLEMENTATION IMPLEMENTATION

RETROFIT

Installation of Installation of automation solutions, automation solutio training and turnkey.training and turnke

RETROFIT

With appropriate preparation the actual upgrade of the turbine with a new controller system requires only a few days offline.

Repowering vs. Retrofit

Dependent on several commercial, technical and legal parameters (e.g.: existing vs. new PTC/FIT/PPM conditions, turbine condition, turbine lifetime, component availability, new tech-

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nical requirements, grid/safety requirements, conditions for runtime extension, etc.), retrofitting could be the more efficient business-case versus repowering.

C


ons, ey.

Performance verification, project sign-off and handover.

COMMISSIONING

Engineering and technician training as well as third-level troubleshooting.

SUPPORT

Advantages of retrofitting ƒƒ E xtend life of turbines ƒƒ Minimal investment for maximum yield ƒƒ Improved efficiency ƒƒ Short installation time ƒƒ Additional functionality ƒƒ Increase visibility into turbine performance with full access to all turbine data

Analyze → develop → implement → use: a systematic approach

ƒƒ Customizable and scalable hardware and software

A systematic approach to retrofitting turbines allows for quick roll-out with minimal downtime required for each upgrade, placing increased performance into the hands of site operators now. Detailed documentation for each step of the retrofit ensures not only quick and efficient installation, but quality work with repeatable results. With detailed documentation of the technical data for the wind turbine, sensors, actuators, and load calculations, analysis is performed by Bachmann engineers in order to understand the optimal controls strategy. Utilization of existing hardware and cabling allows for the setup to be performed with not only minimal downtime, but at a reduced cost.

ƒƒ Independence from the manufacturer ƒƒ Increase operational reliability ƒƒ Flexibility through a modular design ƒƒ Regulatory compliance ƒƒ Adaptability to micro-siting parameters

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WIND ENERGY AUTOMATION SOLUTION  Makes your wind energy solution smarter

Smart, reliable turbine automation High speed park communication (bluecom) Smart grid and power control Open, flexible SCADA system Integrated Condition Monitoring

WebLog Expert CMS analysis Monitoring reporting

CMS Data

Server

Controller integrated CMS extention

Ethernet/OPC UA data network »bluecom« control network Turbine automation system

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Bachmann high-speed Ethernet based protocol


Park Scada Online data, historical data park overview, data base, CMS ISO 10816-21 view

Scada Master Control System (SMCS) Worldwide overview

Ethernet/TCP-IP OPC UA data network

Energy protocol interface

Park controller, grid measurement, grid protection, ...

IEC 60870-x, IEC 61850, IEC 61400-25, Modbus-x, DNP3, ...

switchboard

Park control unit

Power provider

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DESIGNING WIND POWER EFFICIENTLY Wind or industry-specific SCADA system for direct operation

Bachmann‘s Wind Power SCADA offers an easy-to-use engineering tool for wind farm projects. Maximum flexibility and openness ensures rapid implementation, good maintainability and the possibility to execute the installation efficiently. The comprehensive representation of process values according to the IEC 61400-25 interface, not only simplifies internal communication but also provides external operators and energy companies with uniform access to the specific characteristic values.

BEFORE

Limited access

Multi-brand proprietary system

Proprietary protocol

Proprietary SCADA solution

Grid control

AFTER Web-based, open, user access controlled

Bachmann system

OPC UA IEC 61400-25 Standard protocol

WPS SCADA

Grid control

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3rd party


Complete overview at any time The development of Bachmann‘s open, flexible and future-oriented Wind Power SCADA (WPS) system was based on its many years of experience and knowledge acquired in the wind power sector. Using pure web technology as a basis, a wide range of different terminal devices can be used for running the SCADA system – a browser is all that‘s needed to access extensive and detailed information on the entire fleet.

Faster engineering to the target The WPS sector-specific system solution is a perfect addition to Bachmann‘s WindTurbineTemplate (WTT), a turbine controller software, which provides the most important components, analyses and functions for the operational control of a wind turbine. WTT is based on the data structures of the IEC 61400-25 standard and depic ts all process values using the standard compliant data area. This enables standard compliant components created in WPS to be instantiated as objects from the prepared libraries. The process data connection is therefore already completed and the turbine can be visualized with its components by simply using drag and drop to add the instance. This considerable reduction in development effort through the use of library components helps you to achieve your goal faster and more economically.

Field-proven technology for all areas WPS is based on the generic atvise SCADA product from Certec, a company belonging to the Bachmann Group. Thanks to its multiclient server architecture, atvise SCADA provides the ideal basis for WPS. Multi-lingual functionality as well as device and operating system independence complete the portfolio for keeping wind power in view from anywhere in the world. PCs, tablets or smartphones can access a WPS ser ver simultaneously. The required information is scaled automatically and shown correctly on the target device.

Safe operation – made easy Bachmann WPS covers a wide range of operating levels – from the control center to the

farm management system, right through to the individual turbine. Secure access to the turbine is ensured by means of locationdependent priorities and configurable, userspecific access permissions. A thorough logging of all activities at the turbine, as well as commands and parameter changes made via the WPS system, enable full tracking for maintenance in the event of a fault. An extensive reporting system completes the traceability required for plant operations.

Standard communication via the OPC UA connection to external devices and controller systems Using OPC UA as the communication protocol allows external devices or subsystems, such as weather or grid stations, to connect directly to the WPS system, provided the devices also support the IEC 16400-25 compliant structures. If this is not the case, a gateway allows several other protocols such as the energy protocols for example DNP3 in accordance with IEC 60870-103/-104, IEC 61850 or fieldbus protocols, such as Profinet, Profibus, CANBus etc., to be connected and the relevant data to be shown in WPS.

The visualization is adjusted automatically to the display device to ensure ergonomic operation even on mobile devices such as tablet PCs or cell phones.

Benefits of Wind Power SCADA (WPS) ƒƒ Sector-specific SCADA system ƒƒ High scalability, open system ƒƒ Easy visualization on all mobile devices ƒƒ Live process data on all visualization levels ƒƒ Automatic adaption of the graphic solution for PC, tablet or smartphone ƒƒ Standard user management for SCADA and turbine, also online ƒƒ Active status/access control ƒƒ Alarm and data history ƒƒ Service logbook ƒƒ SplitScreen mode ƒƒ Online/offline trending ƒƒ CMS ISO 10816-21 integration

Responsive web design The use of the latest web technologies provides the basis for maximum scalability. HTML5 and scalable vector graphics (SVG) make it possible to display on virtually any browser-enabled terminal device – without the need for additional plug-ins. The visualization is adjusted automatically to the display device to ensure ergonomic operation even on mobile devices such as tablet PCs or cell phones.

ƒƒ Reporting ƒƒ Integrated wind farm/turbine configurator ƒƒ Use of standard OPC UA and IEC 61400-25 communication protocols ƒƒ Availability calculation acc. to IEC 61400-26-1/-3 ƒƒ Online language selection

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WHY CONDITION MONITORING? Focus on efficiency and cost saving

In continuously striving to drive down costs, it is imperative that you can understand what is going on in your machine. By tracking the health of your machine you protect not only your investment, but also optimize your maintenance practices, so that you intervene before consequential damage, but avoid unnecessary measures.

Example of repair costs*

$ 250,000 $ 250,000

$ 200,000 $ 150,000 $ 100,000 $ 50,000 $ 0

$ 60,000 $ 6,000

$ 25,000

with CMS (early planned repair)

without CMS (total loss of the main component)

* based on experiences costs of a total loss are 10 or more times higher than a detected damage in an early stadium and its repair

damaged generator bearing

damaged gearbox bearing

Experience you can rely on Worldwide monitoring of several thousand wind turbines including over 80 different types from a range of manufacturers utilizing both direct drive and geared technologies Power range: 600 kW onshore to 8 MW offshore Supply and installation of condition monitoring solutions for wind energy, maritime and industrial engineering applications 12

 NV-GL certified CMS services: D Hardware and software, remote monitoring, reporting, service and training  ertified CMS – PLC-integrated or standC alone; easily expandable and flexible; standardized and open communication interfaces; suitable for any turbine type  rovision of condition monitoring P solutions specifically configured for wind power, machine construction and maritime applications


Case report One of the gearbox types we monitor is susceptible to a major failure mode. Our monitoring team worked with the customer to identify a frequency band which would reliably inform us of changing conditions on these types of gearboxes. Based on this parameter, an alert was sent to the customer in late August. The customer inspec ted, but could see no obvious problems, and attributed the change to standstill marks; however we were not convinced. The trend continued, and fur ther alarm levels were exceeded. On our advice, and with support from the manufacturer, the customer made the decision to prioritize the exchange of this gearbox.

Benefits Our service monitors the health of your wind turbine allowing you to concentrate on optimizing your procedures. This leads to:

Increased Availability

Early detection of faults allows timely intervention before failure occurs Accurate diagnoses based on our extensive experience and knowledge bank

Risk Management

On exchange it was found that the ring gear had indeed begun to suffer from the damage mechanism, which starts beneath the tooth surface. So it is not always apparent via endoscopy and sometimes even until it is too late.

Our experience delivers in-depth knowledge of your wind turbines, which allows you to: Understand the status of your wind park Confidently challenge the manufacturer or service provider from an informed position Improve risk analysis when considering how long to run with minor faults

Before we found this particular indicator, gearboxes were known to fail catastrophically, destroying the tooth surfaces and bearings. In this case only the pictured gear had suffered any damage, thus saving significant refurbishment costs.

Cost Reduction

Condition based maintenance and maintenance optimization leads to reductions in maintenance cost

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SCADA RETROFIT CASE STUDY Retrofit of SCADA for 155 GE 1.5 sle turbines

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A large US wind farm owner/operator was concerned with the OEM supplied solution and its restrictive nature. They wanted to upgrade the SCADA so security vulnerabilities were patched, and not have features and data access further restricted. Comprehensive data and flexibility for their data analytics program was a primary focus as was using maximum performance data and gaining increased security. With a self-performance model for operation, the flexibility and ease of adapting additional features and analysis within the Bachmann Wind Power SCADA (WPS) solution were also key drivers to go with Bachmann.

Overview With a need to upgrade CPU controllers from the discontinued MP2xx/MPC2xx controller line to Bachmann’s latest MC2xx controller, coupled with the constant threat of cyberattacks tighter security needs, a large owner/ operator in West Texas awarded Bachmann a large SCADA retrofit project for their 155 GE 1.5 sle turbines. Prior to selection as SCADA partner for the site, Bachmann first deployed a 3 turbine, 6 month trial for the site to evaluate the WPS platform risk-free. Customer requirements were fully detailed ahead of deployment which consisted of enhanced security to protect the site against cyber attacks, complete access to turbine data, removal of VisuPro PCs with web based access, site specific curtailment commands, and database sharing access.

Cyber Security The Bachmann M1 system has a multilayer security architecture ranging from 0-5, with 5 being the highest level of security (SSL/TSL) and fulfill the NERC cyber security requirements. With the previous security level set to 0 (no security), site access was granted freely to both operators and hackers alike. Through WPS’ token-based write access, multiple users were able to simultaneously access WPS with write access automatically assigned based on login credentials or proximity to the turbine, while accounting for safety. With user logins and parameter changes saved and archived, operators have full transparency allowing work to be tracked at any time.

Data Access Data access is provided through variables mapped according to the IEC 61400-25, the international standard defining communication for monitoring and control of wind power plants. This ensured that the site was provided open access to their turbine data with standard nomenclature defined for turbine param-

eters. Standardizing turbine data allowed for interpretation of signals regardless of turbine make, allowing the customer to move towards a single SCADA platform for their mixed fleet. The level of data access provided by WPS, along with the flexibility and customization options, allowed the site to free themselves from their OEM dependence. They now could implement additional features (such as site-specific curtailment commands) within WPS using their own internal resources or assistance by Bachmann. WPS’ database sharing allowed for 10 min SCADA data to be exported to the site’s data historian via OPC-DA.

Removing VisuPro PCs During the trial period, WPS operated in parallel to the existing GE SCADA system and the VisuPro PCs. This allowed the customer to evaluate WPS with minimal impact on their operation. Upon successful completion of the trial, the customer chose to remove all VisuPro PCs and rely on Bachmann’s web-based WPS solution for all SCADA operation. Maintenance level access was granted by connecting a laptop directly to the M1 controller located downtower and opening the web-based WebMI turbine visualization on a simple web browser without needing to download any plugins.

Conclusion Upon completion of the WPS retrofit, Bachmann was able to provide a flexible, cost competitive, cyber secure alternative to the OEM, based on IEC standards. The site’s security vulnerabilities were patched, the turbine PCs removed, complete access was granted, and the site was trained to continue developing additional features themselves within Bachmann WPS. With WPS, the site was able to achieve the independence they needed with their next SCADA platform, while ensuring a low cost of ownership would be realized throughout the lifetime of their park.

Benefits of Bachmann’s WPS Retrofit ƒƒ Highest level of cyber security with all logins stored and archived for traceability ƒƒ Complete data access ƒƒ Web based visualization delivered through most web browsers and provided without needing to download any plugins ƒƒ User-defined screens are easily created and stored for quick reference ƒƒ Implement additional features with atvise builder using internal resources ƒƒ Easy to use overlays allow for straight forward comparisons, online/offline trending, and custom reporting ƒƒ Pure Web HMI, allowing for visualization on tablets, smart phones, and computers ƒƒ Display in accordance with open communication standard IEC 61400-25 ƒƒ Data analysis made possible either in graphical or tabular form ƒƒ Event triggered data logging for fault analysis ƒƒ A larm handling and historization ƒƒ O PC UA communication protocol allows external devices or subsystems, such as weather or grid stations, to connect directly to the Wind Power SCADA system

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Retrofit for wind energy EN | Subject to modifications Š 02/2019 by Bachmann electronic

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