Winds of Change Bring Higher Yields

With a retrofit solution, system speed and pitch can be easily adjusted to current needs via secure, web-based remote access. The yaw system and main shaft brake can also be controlled manually. In the event of balancing requirements from grid operators, the Bachmann solution’s definable power setpoints significantly improve the power curve of wind farms, increasing cumulative energy yield and avoiding an entire plant shutdown (see Factbox). In low wind conditions, the intelligent controller also reduces self-consumption, leading to lower operating costs. 

Automatic self-start routines bring the turbine back online automatically and at record speed after grid disturbances, and a manual plant reset can be carried out remotely. A turbine retrofit with Bachmann opens up the possibility of condition monitoring for primary components, such as drive trains, gearboxes and rotor blades. Online diagnostics with Weblog, Bachmann’s condition monitoring system, supports early-stage damage detection and targeted on-site maintenance scheduling, and extends plant service life. It can also help optimize operational strategies and increase annual energy production. For drivetrain faults, the system's detection rate is a remarkable 99%. 
 

Following inventory and performance measurements of the existing system, we analyze data and communication interfaces and identify initial potential for optimization. This is followed by a controller software implementation, including plant documentation, I/O and event lists, as well as load calculations with Bachmann’s Wind Turbine Template (WTT) – based on turbine structures as defined in IEC61400-25. After multiple testing processes – software in the loop (SIL), hardware in the loop (HIL), and real-world conditions, the completed system is installed on site and commissioned.  

As all hardware retrofits and software adjustments are planned and configured in advance, operations are only interrupted for a few days during implementation.

The retrofit makes the best possible use of existing turbine infrastructure. Existing sensors and actuators remain in use wherever possible. Failure-prone or obsolete components are replaced to ensure many years of continued operations. In addition, new controller modules are subjected to a 48-hour test in advance under the most extreme conditions. 

When original parts are no longer available for defective turbine components, controller parameters for any third-party replacements must be reassigned. With existing automation systems from turbine manufacturers, data is not always accessible. With Bachmann's open system, operators have access to all necessary data and are able to make flexible adjustment and optimization decisions.
 

Wind Power SCADA (WPS), Bachmann's web-based SCADA solution, allows any visualization device to be connected to the automation system – from smartphones, to powerful operator terminals. The software framework is based on WTT and incorporates communication standards such as OPC UA as well as IEC 61400-25. With its ready-made plant components and numerous integrated functions, developers can quickly implement new control strategies and easily create additional visualization tools. Together with the scalable hardware concept, operators remain securely and profitably connected to the grid over the long term.