august 17, 2012 intertek test report no. 100413407crt · pdf filewind turbine industries,...

3933 US Route 11 Cortland, NY 13045 Telephone: (607) 753-6711 Facsimile: (607) 753-1045 www.intertek-etlsemko.com

of 72 This report is for the exclusive use of Intertek’s Client and is provided pursuant to the agreement between Intertek and its Client. Intertek’s responsibility and liability are limited to the terms and conditions of the agreement. Intertek assumes no liability to any party, other than to the Client in accordance with the agreement, for any loss, expense or damage occasioned by the use of this report. Only the Client is authorized to permit copying or distribution of this report and then only in its entirety. Any use of the Intertek name or one of its marks for the sale or advertisement of the tested material, product or service must first be approved in writing by Intertek. The observations and test results in this report are relevant only the sample tested. This report by itself does not imply that the material, product or service is or has ever been under an Intertek certification program.

Intertek Testing Services NA, Inc. SD 12.1.2 (11/11/10) Informative

August 17, 2012 Intertek Test Report No. 100413407CRT-007 Project No. G100413407 Mr. Steve Turek Phone: 952-447-6064 Wind Turbine Industries, Corporation Fax: 952-447-6050 16801 Industrial Cir SE email: [email protected] Prior Lake, MN 55372-3307 Subject: Duration test report for the Wind Turbine Industries, Corporation (WTIC) Jacobs 31-20 Wind Energy

System tested at the Intertek Small Wind Regional Test Center (RTC). Dear Mr. Turek, This Test Report represents the results of the evaluation and tests of the above referenced equipment under Intertek Project No. G100413407, as part of the US Department of Energy and National Renewable Energy Laboratory (DOE/NREL) Subcontract Agreement No. AEE 0-40878-02, to the requirements contained in the following standards:

AWEA 9.1 Small Wind Turbine Performance and Safety Standard December 2009 IEC 61400-2 Wind turbines – Part 2: Design requirements for small wind turbines Second edition; 2006-03

This investigation was authorized through signed Intertek Quote No. 500304911, dated May 13th, 2011. A production sample was installed at the Intertek RTC on October 25th, 2011, and commissioned on November 1, 2011. Duration testing began on November 2, 2011 and data collection continued through May 31, 2012. This Test Report completes the duration testing phase of the Jacobs 31-20 Wind Energy System under Intertek Project No. G100413407. If there are any questions regarding the results contained in this report, or any of the other services offered by Intertek, please do not hesitate to contact the undersigned. Please note, this Test Report on its own does not represent authorization for the use of any Intertek certification marks.

Completed by: Joseph M Spossey Reviewed by: Tom Buchal Title: Project Engineer Title: Senior Staff Engineer

Signature:

Signature

Wind Turbine Industries, Corporation Test Report No. 100413407CRT-007 August 17, 2012

of 72 Intertek Testing Services NA, Inc. SD 12.1.2 (11/11/10) Informative

Wind Turbine Generator System Duration Test Report

for the

WTIC Jacobs 31-20 Wind Energy System tested at

Intertek Small Wind Regional Test Center



1.0 Background This test was conducted as part of the DOE/NREL Subcontract Agreement No. AEE-0-40878-02 for the testing of small wind turbines at regional test centers. The WTIC Jacobs 31-20 Wind Energy System was accepted into this program by Intertek and DOE/NREL. The full scope of type testing and AWEA Certification provided by Intertek for the Jacobs 31-20 horizontal-axis wind turbine is covered by this agreement. This test report is a summary of the results of duration testing, and is one of four tests required for the Jacobs 31-20; the other three being power performance, safety and function, and acoustics. Results for these other tests are summarized in their respective Test Reports. The Jacobs 31-20 turbine was installed at Test Station #5 at the Intertek RTC in Otisco, NY. The Jacobs 31-20 is designed for grid-connected power delivery, with a maximum power output of 20 kW. It is designed as a Class II upwind turbine, with speed and power control through side furling and a centrifugal variable pitch governor. The blades of the Jacobs 31-20 drive the low speed shaft of an offset hypoid gearbox with 6.1:1 ratio. The gearbox high-speed shaft drives a brushless three-phase AC synchronous generator with outbound exciter. The generator is rated for 40-180 VAC operation up to 25 kVA. Grid interconnect is provided by a Nexus Nex20 inverter, which fully converts the generator output to single phase 240 VAC for connection to a single/split phase grid. The Nex20 inverter is specifically designed for the Jacobs 31-20 Wind Energy System. The test tower and foundation were designed and approved by ROHN Products LLC. NYS Professional Engineer stamped tower and foundation designs were also provided by ROHN Products LLC. The designs were based off of the Subsurface Investigation and Geotechnical Evaluation detailed in Atlantic Testing Laboratories report number CD3119E-01-05-10 for the Intertek RTC. The electrical network at the testing location is single/split phase 120/240 VAC at 60 Hz. Refer to the wiring diagrams in Appendix A for additional detail. A summary of the test turbine configuration and manufacturer’s declared ratings can be found in Table 1 below.

2.0 Test Objective The purpose of the duration test was to validate the operational abilities of the Jacobs 31-20 shown on page 2, and described in detail in Table 1. This was done through monitoring reliable operation of the turbine over a period of at least 6 months. Factors such as structural integrity, material degradation, protection of the wind turbine, and dynamic behavior of the wind turbine help determine if the product operates as designed by the manufacturer.



3.0 Test Summary This test was conducted in accordance with the American Wind Energy Association Small Wind Turbine Performance and Safety Standard dated December, 2009. The duration test was also conducted in accordance with the second edition of the International Electrotechnical Commission’s (IEC) 61400-2 Wind turbines – Part 2: Design requirements for small wind turbines, dated March, 2006. Hereafter, these testing standards and their procedures are referred to as the “Standards.” For the purpose of the duration test, the following considerations apply:

1. The turbine system is connected to the electrical network at the Intertek RTC through a subpanel. All

wiring and components on the turbine side of this subpanel are considered part of the turbine system. 2. The turbine system includes all control equipment including wiring between the up-tower equipment and

the equipment located in the data shed. The test configuration consists of: a. Up-tower turbine assembly – Rotor blades, gearbox, drive shaft, shaft brake, generator, up-tower

junction box, tail, and tower-top stub mast assembly b. Down-tower assembly - Lattice tower, manual brake hand crank, lightning protection, turbine

disconnect, and foundation c. Equipment inside data shed – Turbine disconnect and grid-tie inverter d. Meteorological tower, test instrumentation, junction boxes and wiring, and data acquisition e. Power measurement equipment; installed between the AC output of the inverter and the Intertek

subpanel referenced in 1 above The turbine was installed on a free-standing 33.53 meter (110 foot) lattice tower. The wire run from the base of the tower to the power measurement equipment in the data shed is approximately 91.4 meters (300 feet). Table 1 further defines the configuration of the wind turbine system tested for this report and also provides the manufacturers declared ratings and specifications. The power measurement equipment used for measurement of electric power consists of both a current transformer and power transducer used to measure current and voltage to determine electric power output in accordance with the Standards. The power measurement equipment is connected between the AC output of the grid-tie inverter and the Intertek subpanel. The location of power measurement equipment encompasses the combined consumption and production of the entire turbine system. The wiring diagrams, which are shown in Appendix A, give detail on typical single/split phase wiring scenarios as well as test site specific detail. The database analyzed to produce the results within this report is sufficient enough to satisfy the hourly test requirements of the duration test. No significant wear, corrosion, or degradation of turbine system components of the Jacobs 31-20 was found as a result of the detailed post-test inspection. As a result of satisfactory completion of the duration test and post-test inspection, the Jacobs 31-20 has met the criteria for reliable operation that is a requirement of the duration test. Therefore, the Jacobs 31-20 successfully completed all of the requirements for the duration test . Additional supporting detail can be found within this report. Hourly power production data can be found in Section 9 of this report.



Turbine manufacturer and address Wind Turbine Industries, Corporation

16801 Industrial Circle S.E. Prior lake, Minnesota 55372

Model 31-20

Gearbox manufacturer Wind Turbine Industries, Corporation

Model: 20kW, Part Number: 60717-900 Serial Number: 03150030

Gearbox specifications Offset hypoid design 6.1:1 gear ratio

Generator manufacturer Winco Inc; Model 20PS4G-27

WTIC Part Number: 395358-000 Serial #: W2148

Generator specifications 20 kW, 40-180 VAC, 0-40 Hz 3-phase, 450-1050 RPM

Inverter manufacturer Nexus

Model #: NEX20 Serial #: 100

Inverter specifications 20 kW, 240 VAC, 60 Hz TUV listed - UL 1741

Rotor diameter 9.45 m (31.0 ft.) – verified by Intertek Hub height 35.9 m (117.0 ft 8.0 in.) Swept area 70.1 m2 (755.0 ft2 ) IEC 61400-2 SWT Class (I, II, III, or IV) II Tower type(s) Lattice Rated electrical power 20.0 kW Cut-in wind speed 4.5 m/s (10.1 mph) Rated wind speed 11.6 m/s (26.0 mph) Survival wind speed 53.6 m/s (120.0 mph) Rotor speed range 175 – 185 rpm Fixed or variable pitch Variable Number of blades 3 Blade tip pitch angle 1°

Blade manufacturer Advanced Aero Technologies. Inc Fiberglass SNs - 310020CGA1849, 310020CGA1854,

310020CGA1852

Control system software Proprietary System, Horner Display unit HON:1.13, Oztek Control Board DSP:1.03

Table 1 – Test turbine configuration and manufacturer’s declared ratings

4.0 Judgments, Exceptions, and Deviations There were no judgments, exceptions, or deviations from the Standards for the purposes of this test report.



5.0 Test Site Description 5.1 Test Site The RTC has class IV winds, and can accommodate turbines that produce 120V or 240V, 60 Hz power. It is on a hilltop, with previous agricultural land use, near the township of Otisco, NY. It was surveyed, analyzed and developed to be a test site for Intertek’s customers. The Jacobs 31-20 was tested at RTC site #5, which has no prominent obstructions in the valid measurement sector, as determined by obstacle assessment in accordance with the Standards. The meteorological equipment tower is due south, 23.6 m (77.5 feet) from the turbine, exactly 2.5 times the diameter of the rotor, as recommended in the Standards. All buildings and potential obstacles were identified and defined in the topographical survey, and were considered during obstacle assessment prior to commencement of testing. Figure 1 below is a topographical survey map showing the Intertek RTC in 10 meter elevation intervals. The Jacobs 31-20 was installed at RTC site #5, which is shown in the red box in Figure 1.

Figure 1 - Intertek RTC topographical survey



Figure 2 below shows a zoomed view of the turbine and meteorological tower locations identified in the red box in Figure 1.

Figure 2 – Jacobs 31-20 and meteorological tower locations

For the duration test there is no requirement to decrease the measurement sector where there is the potential for airflow disturbances. For power performance testing a final valid measurement sector of 230° true to 260° true was observed as a result of site calibration. Over the 7 month testing period winds were out of this range for only 10% of the time.



6.0 Test Equipment Description Table 2 below shows the equipment that was used during the duration testing of the Jacobs 31-20. Serial numbers and instrument calibration details are also provided in the table. All instruments were properly calibrated according to the Standards for the entire testing period for the duration test. Calibration certificates are included in Appendix C.

Description Manufacturer Model Serial No Calibration Date

Calibration Due

Primary Anemometer Adolf Thies GmbH 4.3351.00.141 05110086 21-Sep-2011 21-Sep-2012 Reference Anemometer Adolf Thies GmbH 4.3351.00.141 05110087 21-Sep-2011 21-Sep-2012

Wind Vane Adolf Thies GmbH 4.3150.00.000 04100018 08-Aug-2011 08-Aug-2012 Pressure Sensor Vaisala Oy PTB330 F1420001 12-Aug-2011 12-Aug-2012

Temperature/RH Sensor Adolf Thies GmbH 1.1005.54.241* 85764 12-Aug-2011 12-Aug-2012 Power Transducer Ohio Semitronics DMT-1040EY40 A333** 24-Oct-2011 24-Oct-2012

Current Transformer Ohio Semitronics 13480 A333** 24-Oct-2011 24-Oct-2012 *Model # differs on calibration certificate; the model # listed in this table is correct **Intertek calibration database Asset #; PT and CT calibrated as a system

Table 2 – Equipment used in the power performance test A National Instruments cDAQ-9178 backplane and NI-9203 +/- 20 mA 8-channel current module were used for logging the output signals from the sensors in Table 2 above. A proprietary LabVIEW program was used to collect and filter data that is stored in raw and 1 Hz data files on the Intertek RTC site computer. Prior to testing a signal verification procedure was carried out on the data acquisition system by Intertek to verify the signals of each transducer against recorded values from the LabVIEW program. Table 3 below summarizes the results of the signal verification

Measurement NI 9203 Channel Injected Signal {mA}

Measured Value {mA}

Offset {mA}

4.000 4.000 0.000 12.000 12.000 0.000 Primary wind speed 0 20.000 20.000 0.000 4.000 4.000 0.000

12.000 12.000 0.000 Reference wind speed 1 20.000 20.000 0.000 4.000 4.000 0.000

12.000 12.000 0.000 Wind direction 2 20.000 20.000 0.000 4.000 4.000 0.000

12.000 12.000 0.000 Relative humidity 3 20.000 20.000 0.000 4.000 4.000 0.000

12.000 12.000 0.000 Temperature 4 20.000 20.000 0.000 4.000 4.000 0.000

12.000 12.000 0.000 Barometric Pressure 5 20.000 20.000 0.000 4.000 4.000 0.000

12.000 12.000 0.000 Output power 6 20.000 20.000 0.000

n/a 7 not used not used n/a Table 3 – Signal verification results



The data acquisition system is located inside the Intertek RTC control building, and all signals are measured at this location. This is also the location of the turbine disconnect and grid-tie inverter, and thus is also where power measurements are made. The data is stored on two separate computers at the Intertek RTC, and is also stored in the Intertek project file. The power measurement equipment is located inside the control building at an approximate wire run length of 91.4 meters (300 feet); which satisfies the required wire run length in the Standard.

Figure 3 displays the arrangement of the meteorological tower with dimensions of instrument locations. The height above ground level to the centerline of the cups of the primary anemometer of 35.87 meters is the same height above ground level as the hub height of the Jacobs 31-20. The reference anemometer and the wind vane are installed at the same height of 33.87 m, and the temperature and pressure sensors are installed at the same height of 21.5 m.

Figure 3 - Meteorological tower and instrument locations



7.0 Test Procedure

7.1 Test requirements According to the Standard, the turbine will pass the duration test when it has achieved:

� Reliable operation during the test period � 6 months of operation � 2500 hours of power production in winds of any velocity � 250 hours of power production in winds of 1.2 Vave (10.2 m/s for Class II) and above � 25 hours of power production in winds of 1.8 Vave (15.3 m/s for Class II) and above � 25 hours in wind speeds of 15 m/s and above

Reliable operation is defined as:

� Operational time fraction of at least 90% � No major failure of the turbine or components in the turbine system � No significant wear, corrosion, or damage to the turbine components � No significant degradation of produced power at comparable wind speeds

7.2 Data Collection Measurement procedures and data collection were conducted in accordance with the Standard. Data was sampled at a rate of 1 Hz. The period for all average, maximum, minimum, and standard deviation values was 10 minutes, as required by the Standards. No turbine status signal is provided by the turbine controller; therefore, one was not monitored during this test. Meteorological data and the turbine output power signals were gathered by the NI 9203 module and stored in daily spreadsheet files on the Intertek data shed computer. The spreadsheet files are where all analysis according to the Standards took place.



8.0 Uncertainty The uncertainty of the following items is estimated in this section:

� Hours of power production � Operational time fraction � Highest instantaneous wind speed

8.1 Hours of power production Intertek assumes that the turbine was producing power for the entire 10-minute interval when the average output power at the power transducer is greater than 0 Watts. This method likely yields a higher number of hours of power production for wind speeds near cut-in of the Jacobs 31-20. The turbine may have only been producing power for half of the 10-minute interval, but the net result of the 10-minute interval was positive. At higher wind speeds this is much less of an overestimate. Intertek estimates that the number of hours of power production in all wind speeds may be 20% less than calculated. Given that the database extended for 7 months and greater than 3650 hours of power production were observed, Intertek is confident that the hourly requirements indicated in the Standard were satisfied. For the hours of power production in winds above 10.2 m/s and 15.3 m/s the uncertainty in the measured wind speed is the primary factor of uncertainty. Assuming a 0.5 m/s uncertainty in wind speed, the hours of power production reduce to 464 hours (above 10.7 m/s) and 27 hours (above 15.8 m/s). Both of these values are above the minimum number of hours required of 250 and 25 for winds above 10.2 m/s and winds above 15.3 m/s, respectively. 8.2 Operational time fraction The total test time is 5088 hours. Assuming that the classification of time during which the turbine is known to be non-operation, TN, is wrong by a very conservative assumption of 10%, the operational time fraction would still be greater than 96%. 8.3 Highest instantaneous wind speed The uncertainty in the wind speed measurement is based on 0.0289 m/s calibration uncertainty, 0.0866 m/s + 0.866 % operational uncertainty, 2% uncertainty due to terrain, 1% uncertainty due to mounting, and 0.66% uncertainty in the data acquisition. For the maximum instantaneous wind gust of 32.8 m/s, the uncertainty is 0.82 m/s.



9.0 Test Results 9.1 Operational Time The test turbine system was installed on October 25, 2011. The system was commissioned and ready for testing on November 1, 2011. The duration test started on November 2, 2011 and was completed on May 31, 2012, after sufficient data was collected to satisfy the hourly test requirements. The test covered a period of 224 days. The commissioning checklist from the installation can be found in Appendix D. 9.2 Months of Operation The duration test was conducted over a period of 7 months, or 212 days, from November 2, 2011 through May 31, 2012. The turbine was parked on June 15, 2012 and removed from the tower on July 24, 2012 for post test inspection. 9.3 Hours of Power Production Table 4 below indicates the number of power production hours observed during the 7 month test duration.

Hours of Power Production IEC SWT Class II – V ave = 8.5 m/s

Wind Speed Measured Required Pass/Fail > cut in 3663 2500 Pass

> 1.2 Vave 559 250 Pass > 1.8 Vave 37 25 Pass > 15 m/s 44 25 Pass

Table 4 – Duration test hourly power production results for the Jacobs 31-20

9.4 Operational Time Fraction

The operational time fraction is defined by the following equation:

where:

TT is the total time period under consideration, TN is the time during which the turbine is known to be non-operational, TU is the time during which the turbine status is unknown, and TE is the time which is excluded in the analysis. The overall operational time fraction of the combined wind turbine system in the total test period was 97 %. Table 5 below displays the values that were used for determination of overall operational time fraction.

Operational Time Fraction Values Variable Hours

TT 5088 TN 140 TU 178 TE 268

Table 5 – Hourly results for operational time fraction values for the Jacobs 31-20



One of the reasons for wind turbine system downtime (TN) during the test period relates to periods of data in which the turbine would be expected to be exporting power, but was instead consuming the typical amount of power needed to remain in a stand-by state (around 45 Watts). This inverter stand-by accounted for 61% of the 140 hours included in TN. The remaining 39% is related to the replacement of a tower bolt that came loose during the early stages of testing. On November 7, 2011 a bolt and nut were found at the base of the tower that were not discovered during previous observations under the turbine tower. One of the cross braces on the SSL Rohn tower, just below the 20 foot level, was clearly missing a bolt as the cross-brace was loose from the tower.. The brake was immediately applied to the turbine, and WTIC was contacted. On November 9, 2011 WTIC installers climbed the tower to check for loose bolts; no other loose bolts were found. The reasoning for the bolt found on November 7 was determined to be related to the installation running late into the evening and simply being missed. The primary reason for time related to unknown status (TU) of the turbine system during the test period is related to periodic downtime of the Intertek data acquisition system. 100% of the 178 hours of unknown time is due downtime of the Intertek data acquisition system for software modifications and powering down for other installations on the test site. The primary reasons for excluded time (TE) in the analysis are related to a combination of grid outages and turbine shut downs for acoustic testing. The largest contributor for excluded time was grid outages. In early March 2012 a power outage occurred that ended up in 10 days of lost data. Greater than 87% of the excluded time was due to this power outage. All values reported in Table 5 above were used in the final determination of power production hours in Table 4 above. 9.5 Environmental Conditions In order to understand environmental conditions over the testing period, several statistics are required by the Standard. These values are summarized in Table 6 below.

Environmental Conditions During Test Period Description Value

Highest instantaneous wind speed 32.8 m/s Highest 10-minute average wind speed 20.9 m/s Highest 10-minute average temperature 31.6 °C Lowest 10-minute average temperature -21.1 °C

Turbulence intensity @ 15 m/s bin 16.8 % Table 6 – Environmental conditions during test



9.6 Power Degradation One of the criteria for reliable operation is that the turbine should experience no significant power degradation over the test period at comparable wind speeds. For each month of the duration test, the power levels were binned by wind speed at integer values. For each wind speed, a plot was made with the binned power levels as a function of time. The plot was analyzed for any visible trends in power production. Figure 4 below shows the plot for each wind speed over the duration of the test period. No visible trends were observed during the 7 month testing period. For this plot, wind speeds between 4 m/s and 18 m/s are shown. Data points are only included on the plot if there are more than 6 data points (60 minutes) in the wind speed bin. Where there are gaps in the wind speed plots in November, April, and May are periods where high winds were not recorded at the test site.

Figure 4 – Power degradation plot for the Jacobs 31-20



9.7 Dynamic Behavior During the test period, the turbine and tower were observed for any potentially harmful turbine or tower dynamics. The dynamic behavior of the Jacobs 31-20 was observed under all operating conditions in wind speeds ranging from below cut-in to above 20 m/s. Formal and documented observations totaled more than 5.5 hours. The breakdown of documented observations is as follows:

� Approximately 2 hours of observation near 5 m/s � Approximately 1.3 hours of observation near 10 m/s � Approximately 1 hour of observation near 15 m/s � Approximately 1.2 hours of observation near 20 m/s

Excerpts from the site logbook for several documented observations are provided below:

November 3, 2011 Wind speed: 5 - 15 m/s Wind direction: SW “The turbine tail vane appears to rattle in higher and/or turbulent winds…will continue to monitor. Also noticed what appears to be a spring on the tail vane frame that is connected to the back of the gearbox that vibrates in periods of high and/or turbulent winds. Also observed noticeable vibration of the cross members at the base of the turbine tower.”

November 11, 2011 Wind speed: 5 -15 m/s Wind direction: W

“Brake applied at 8:15 am to set up for background noise measurements. Brake applied in winds between 6 – 8 m/s; no issues, turbine came to complete stop easily. Tower vibration seemed to be less than what I had noticed before, likely due to the fact that the missing bolt had been replaced. Wind generally out of the west. Background measurements started at 9:30 am; winds upwards of 10 m/s. After releasing brake for turbine noise measurements, observed the turbine for 10-15 minutes. The turbine tower top is very dynamic. Deflections of +/- 1 foot are seen. When the turbine tail furls is when the tower is most dynamic. Very windy today, so the activity is high.”

November 14, 2011 Wind speed: 10 -25 m/s Wind direction: SSW

“Wind velocity is high, and turbulent. The turbine ranges between 1000 and 18000 Watts power output due to direction change and furling of the turbine. Wind generally SSW. Everything appears to have been operating normally over the weekend. Checked fault log on inverter; one fault in fault history for today. The ‘alarm’ was at 6:59 am for “AC Line Over Current”, and was cleared at 6:59 am.”

February 17, 2012 Wind speed: 5 m/s Wind direction: WNW

“Winds between 4 and 7 m/s out of the WNW. Turbine observed for 10 minutes, everything seems to be OK. No abnormal tower vibrations or dynamics. There was a noticeable ‘hum’ coming from what is assumed to be the gearbox and generator. It seems to be most notable when there is a change in rotational speed in the drive train. Will continue to monitor throughout testing period.”

Over the 7 month testing period the turbine was observed for numerous hours that were not formally documented in the site logbook. Throughout the testing period observations of the turbine and tower remained consistent. At all times throughout the duration of testing the turbine’s yaw movement appeared to track the wind within approximately 5 degrees. 9.8 Post-Test Inspection The post test inspection was performed on July 24, 2012. The results are documented in Appendix E. The inspection did not yield any significant findings that relate to excessive wear, degradation, and corrosion that could lead to potentially harmful situations over the expected 20 year life of the Jacobs 31-20. Due to the lack of deleterious findings during the post-test inspectio n, the Jacobs 31-20 was deemed to have met the reliable operation requirement for the duration test .



A.0 Appendix The following sections can be found within this Appendix:

� A Wiring diagrams

� B Pictures of the test site � C Calibration certificates � D Commissioning checklists � E Post-test inspection



A Wiring Diagrams A.1 Typical wiring diagram for Jacobs 31-20



A.2 Block diagram of Jacobs 31-20 setup at Intertek RTC



B Pictures of the test site B.1 North



B.2 Northwest



B.3 West



B.4 Southwest



B.5 South, and meteorological tower



B.6 Southeast



B.7 East



B.8 Northeast



C Calibration certificates C.1 Primary anemometer



C.2 Secondary anemometer



C.3 Wind vane



C.4 Barometric pressure sensor



C.5 Temperature/RH sensor



C.6 Power measurement system



C.7 Post-test primary anemometer calibration



D Commissioning checklists This section provides the minimum content requirements for the turbine commissioning plan and associated checklists. D.1 Overview The commissioning checklists can be thought of as a compilation of multiple individual checklists that must all be complete before the test can begin. The major sub-checklists in the commissioning process are outlined below:

• Procedures and documentation • Safety checklist • Turbine checklist • Data acquisition system checklist

Special care should be taken on any specific safety devices and locking mechanisms. D.2 Procedures and documentation checklist This section is used for establishment of protocols with an emphasis on safety.

Engineer Joseph Spossey Jacobs 31-20 - Test Station 5

Date October 3, 2011

Item Compliant? Comment

Expected power curve data provided by manufacturer yes Located in Intertek project file

Wiring diagrams provided by manufacturer yes Located in Intertek project file

Project documentation posted and available to Intertek personnel yes Located in Intertek project file

Manufacturer provided commissioning checklist No None provided D.3 Safety checklist Safety is a primary concern during the test and several actions should be taken to ensure the test is conducted as safely as possible.




Locks on building door yes Only Intertek personnel allowed access

Hazard zone established yes Located in Intertek project file

911 Emergency Services aware of test location yes Located in Intertek project file

Fire extinguisher on site yes Located in site building

First aid kit on site yes Located in site building

Building kept clean and free from debris and unnecessary obstructions yes Clean

Site clean and clear from debris yes Clean



D.4 Turbine checklist


Date November 1, 2011


1. Commissioning Background Commissioning can begin after the tower and turbine have been erected and all wiring tasks have been completed according to specification. A commissioning checklist was not provided to Intertek by Wind Turbine Industries. At the time of the installation, a final version of the operations manual had not been provided. After all wiring was confirmed by the installer of the Jacobs 31-20, commissioning mainly consisted of verification of power export to the grid and successful operation of the brake and disconnects.

2. Commissioning Sequence and Checklist Ensure turbine brake is engaged and locked, turbine disconnect at tower base is open, inverter disconnect is open, breaker in Intertek sub panel open.

yes Performed by installer

Recheck all tower and wind turbine fasteners. yes Performed by installer Recheck all wiring connections. yes Performed by installer Wind speeds should be light to moderate. yes Wind speed hovering near 10 m/s Close breaker in Intertek sub panel yes Verified Disengage both disconnects (at inverter and tower base). yes Verified

Disengage brake; verify rotation of rotor blades. yes

Upon release of brake, rotor began spinning immediately. Visual

observation of approximately 100 rpm verified.

Observe (visual and audible) rotor rotation for obvious issues yes No issues Verify inverter power on, and begin 5 minute countdown for grid monitoring and turbine output sensing yes Verified

Verify export of power to grid yes

After 5 minute countdown the contactors in the inverter engaged and power began exporting to the

grid. As wind gusts occurred, power reached near rated power (20000 W). Inverter display for power output was within 5% of the value observed on

data acquisition display as measured by the power transducer.

Engage brake to verify function yes

Brake engaged in winds of approximately 12 m/s. Turbine

stopped easily and, once the brake was fully engaged, no rotation was

observed.

Release brake, verify export of power to grid yes Verified

Continue observation Yes Observe operation of turbine and system for 20 minutes to ensure

proper operation.



D.5 Data acquisition system checklist




Height to centre of rotor; hub height n/a Hub height = 35.87 m (117.67 ft)

Meteorological tower vertical within 2° yes Verifie d

Primary anemometer

Type and serial number verified against test equipment list yes Equipment verified in the field

Instrument calibrated yes Calibration sheets on file

Calibration date acceptable yes Range acceptable for test

Vertical boom level within ± 2° of tower yes Verifi ed

Instrument in same plane as vertical boom yes Verified

Height to centre of cups, above ground level yes 35.87 m (117.67 ft)

Signal verified from instrument output to DAQ yes 4, 12, and 20 mA signals injected at

instrument connection point with Fluke 741B process Calibrator

Data cables secure yes Cables secured down dower, through

conduit, to field board, and through conduit to data shed

Secondary anemometer Type and serial number verified against test equipment list yes Equipment verified in the field



Horizontal boom 90° to tower yes Verified



Height to centre of cups, above ground level yes 33.87 m (111.12 ft)





Wind direction transmitter Type and serial number verified against test equipment list yes Equipment verified in the field


Calibration date acceptable Yes Range acceptable for test




Height to horizontal axis of rotation, above ground level yes 33.87 m (111.12 ft)







Temperature/Humidity sensory Type and serial number verified against test equipment list yes Equipment verified in the field


Calibration date acceptable yes Range acceptable for test Horizontal boom 90° to tower yes Verified Vertical boom level within ± 2° of tower yes Verifi ed


Height to instrument, above ground level yes 21.5 m (70.54 ft)

Thermal radiation shield utilized yes Verified

Signal verified from instrument output to DAQ yes

4, 12, and 20 mA signals injected at instrument connection point at tower junction box with Fluke 741B process

Calibrator



Barometric pressure transducer Type and serial number verified against test equipment list yes Equipment verified in the field






Height to center of instrument, above ground level yes 21.5 m (70.54 ft)





Down tower junction box

Secured to field board yes Down tower box installed at the base of

tower and conduit extended to field board box

Supplied power yes Supplied through conduit to field board

Grounded properly yes Proper enclosure ground utilized

Data cables secure yes Cables run through conduit to data shed

from field board. Power and signal cables are in individual dedicated conduit.



Power transducer Type and serial number verified against test equipment list yes Equipment verified in the field

Instrument calibrated yes Calibration sheet on file


Installed after inverter yes Verified

Installed with CT matching test equipment list yes Verified

Data cables secure yes Cables routed safety/securely inside control building

Data acquisition system (DAS)

All signals verified yes 4, 12, and 20 mA signals injected at


All signals acceptable yes No signal losses observed

All signals recorded yes Signals read were identical to injected signal.



E Post-test inspection E.1 General The following is a summary of the post-test inspection performed on the WTIC Jacobs 31-20. The up-tower assembly was inspected at the Intertek RTC as the turbine was disassembled. The post-test inspection is supported by numerous photographs; some of which are included in this Appendix and the rest are maintained in the Intertek project file. There were no signs of wear, degradation, or corrosion on the down-tower disconnect switch, wiring, or electrical components installed inside the Intertek RTC control building throughout testing. Photographs of the condition of the down-tower and electrical components are not included in this Appendix, and are maintained in the Intertek project file. E.2 Findings and notes Summary of findings for inspection performed at Intertek RTC on July 24, 2012:

1. Tail assembly a. Visual inspection and disassembly of vane assembly. b. Overall assembly is in good condition. c. Significant accumulation of dirt at assembly joints and on nuts/bolts securing the assembly joints;

see photos 1 and 2. d. All bolt paint markings from pre-test inspection remain in same location, showing that no bolts

loosened during the testing period. e. While disassembling, a single bolt sheared off – likely the result of over tightening during

installation. f. Minor corrosion on welds joints; see photo 3. All welds inspected and appear to be in good

condition and do not exhibit signs of degradation or corrosion. g. The two rod and spring assemblies on the tail assembly are in poor condition. The coating on the

springs has chipped off in many locations and there is corrosion on the spring coils. See photo 4 for identification of the rod and spring assemblies prior to testing, and photo 5 for post-test corrosion and chipping of coating. Wind Turbine Industries should investigate this finding further to determine a more suitable level of protection for the springs.

h. In dynamic observations of the turbine during the test period, the sheet metal tail could be heard vibrating in the wind. This was simulated while the tail was on the ground, and the vibration appeared to be related to bolt spacing on the horizontal support running across the tail vane. Wind Turbine Industries should investigate this finding further to ensure proper securement of the tail vane.

2. Nose cone

a. Visual inspection and removal from turbine. b. Overall in good condition. c. No wear, degradation, or corrosion identified. d. Nose cone appears to be in similar condition as when installed. e. See photo 6 for nose cone condition.



3. Rotor blades – Surface condition a. Blade SN – 310020CGA1854

i. Visual inspection and disassembly from hub/governor performed. ii. Considerable build up of dirt and grease on the downwind surface of the blades and at

the connection to the hub/governor. The dirt and grease were easily removed with water and a rag; see photo 7. The dirt and grease on the downwind surface of the blades was consistent for all three blades.

iii. All bolt paint markings from pre-test inspection still in line. iv. Some minor accumulation of dirt and grease on bolts, but no sign of degradation or

corrosion; see photo 8. v. Blade surface in good condition; aside from dirt and grease mentioned previously. Only

very minor impacts and abrasions identified; see photo 9. Leading edge tape still in great condition. No signs of significant wear or degradation.

vi. No other findings on this blade. vii. Generally all three blades were in similar condition, but blade 1854 was in best condition

of the three. b. Blade SN – 310020CGA1849

i. Visual inspection and disassembly from hub/governor performed. ii. Dirt and grease build up is similar to that of blade 1854. iii. All bolt paint markings from pre-test inspection still in line. iv. Similar accumulation of dirt and grease on bolts and blade washer of blade 1854. v. Blade surface in good condition. Two minor impacts and delamination identified; see

photos 10 and 11. Two scuffs were identified on the blade surface, but were the result of minor contact with the crane support during decommissioning. Leading edge in good condition, aside from delamination identified in photos 10 and 11. No signs of significant wear or degradation.

vi. No other findings on this blade. c. Blade SN – 310020CGA1852

i. Visual inspection and disassembly from hub/governor performed. ii. Dirt and grease build up is similar to that of blade 1854. iii. All bolt paint markings from pre-test inspection still in line. iv. Similar accumulation of dirt and grease on bolts and blade washer of blade 1854. v. Blade surface in good condition; aside from dirt and grease mentioned previously. Only

minor impacts and delamination identified, similar to that of blade 1854. Two scrapes were identified near the leading edge of the blade close to the root. These were identified as scrapes, and not surface cracks, and were believed to be caused either by debris or during installation or decommissioning; see photos 12 and 13. Leading edge in good condition. No signs of significant wear or degradation.

vi. No other findings on this blade. d. Mounting of blades to hub/governor

i. Visual inspection after removal from hub/governor. ii. Minor corrosion at blade root connection to hub/governor. Blade slips over a shaft, and is

secured to the hub via bolted connection at two locations. See photo 14 and 15 for understanding of blade mounting to the hub; taken during the pre-test inspection. See photos 16 and 17 for general conditions of blade connection during post-test inspection.

iii. Blade spring assembly (spring holder, springs, spring hub plate, and hardware) all generally in good condition. Spring length during installation was stretched a total of 4 inches from a resting length of 19.5 inches (loaded length of 23-½ inches). During post test inspection this was measured to be 23-¼ inches. Wind Turbine Industries should specify intervals for verification of spring tension in order to ensure proper usage of springs for normal operation.

iv. Silicone and rubber seals were used to prevent ingress of water/moisture into blade root; seals were in good condition, and silicone appeared to perform as intended.



v. Generally all three blades were in similar condition. All welds visually inspected and appear to be in good condition.

vi. Assembly does not exhibit signs of significant wear, degradation, or corrosion.

4. Hub/Governor and gearbox a. Visual inspection during blade removal. b. Governor generally in similar condition to what was documented during pre-test inspection.

Some minor corrosion on the surface of the centrifugal pitch system and gearbox drive shaft connection; see photos 18 and 19.

c. Build up of dirt and grease on rear gearbox enclosure surface where connection to the tail assembly occurs; see photo 20.

d. Minor surface corrosion on the gearbox enclosure. e. Grease fittings, clamps, and hardware all appear to be in good shape and do not exhibit signs of

wear or degradation. f. Gearbox oil was sampled and sent out for analysis along with a sample of new oil of the same

type used during testing. Following guidance from ANSI/AGMA/AWEA 6006-A03 Standard for Design and Specifications of Gearboxes for Wind Turbines, Annex F Lubrication selection and condition monitoring, the oil sample from the gearbox was determined to be in poor condition. The used oil had a light brown color, as compared to the yellow color of the control sample. The ISO code for the control sample was 21/19/14, whereas the code for the used sample was 24/21/13. A dirty system is classified as -/21/18 and new oil is classified as -/17/14 according to Annex F Table F.2. This change in ISO code indicates a higher number of particles with a size of greater than 4 µm and greater than 6 µm were found in the used sample. Additionally the parts per million of iron present in the used oil sample jumped from 0 (control) to 67 (used), indicating wear of gears, shafts, and bearings, or the presence of rust. The viscosity of the oil went from 103.7 cSt (control) to 95.15 cSt (used); a reduction of 8.2%. The water content more than doubled from 0.0147 % to 0.0376 %. According to ANSI/AGMA/AWEA 6006-A03, this type of wear is borderline acceptable for a 6 month sample, as defined in Table F.4. It should be noted that the gearbox was in use for over 7 months. Wind Turbine Industries should consider this when specifying maintenance intervals for the gearbox. No maintenance was performed on the Jacobs-31-20 during the duration test.

g. Overall assembly does not exhibit signs of significant wear, degradation, or corrosion, but attention should be paid to maintenance intervals of the gearbox.

5. Drive shaft, shaft brake, and generator

a. Visual inspection during disassembly b. Drive shaft still in excellent condition. During inspection, the shaft was rotated easily by hand.

Rotation was carried out via direction rotation of the shaft itself, as well as rotation of the hub, once the blades were removed. Rotation seemed normal, with very little slag or resistance. No corrosion on driveshaft, shaft couplings, or shaft brake.

c. Shaft brake in excellent condition. Pads and caliper show little signs of wear. Rotor in good condition and is barely worn.

d. Photo 21 shows the shaft assembly near the generator, with the shaft brake. Photo 22 shows the shaft and coupling at the output of the gearbox. Photo 23 shows the shaft and minor corrosion on the generator input shaft.

e. Generator enclosure has minor corrosion. Generator could not be disassembled in the field for inspection. Alternatively, the exciter windings were inspected and the insulation on the windings had not been compromised during testing. Considering that the windings of the generator have a higher degree of environmental protection, there is no reason to suspect wear or degradation of the internal components of the generator.

f. The generator terminal box, mounted on the generator enclosure and stub mast frame, had no corrosion on the exterior surface or interior components.

g. Assembly does not exhibit signs of significant wear, degradation or corrosion.



6. Stub assembly a. Visual inspection during disassembly. b. All paint markings on bolts/nuts are in line. c. All welds visually inspected and do not show signs of wear or corrosion. d. No signs of corrosion, wear, or degradation.

7. Conclusion

Given the nature of the findings of the post-test i nspection the Jacobs 31-20 is deemed to have met the criteria for reliable operation as defined by the Standard . A majority of the findings are related to issues that may be corrected upon definition, and proper follow through, of maintenance procedures and intervals. Wind Turbine Industries should further assess the wear, corrosion, and degradation identified within this test report, and determine proper counter measures to improve upon the likelihood of reliable operation. The wind regime and environmental conditions that the Jacobs 31-20 was exposed to at the Intertek RTC can be considered rare, and are a good basis for the assessment of reliability, and the probability of achieving expected life.

.



E.3 Supporting photographs

Photo 1 – Accumulation of dirt and corrosion at tail vane assembly joints

Photo 2 – Accumulation of dirt and corrosion on tail vane assembly hardware



Photo 3 – Minor corrosion on welded joints of the tail assembly

Photo 4 – Rod and spring assemblies on tail assembly during pre-test inspection



Photo 5 – Cracking of coating and corrosion on spring coils of rod and spring assembly during post test inspection

Photo 6 – Nose cone condition



Photo 7 – Dirt and grease on downwind surface of blade. Consistent on each blade, and easily

removed with water and a rag.

Photo 8 – Blade washer and bolt/nut for connection of blade to hub/governor



Photo 9 – Minor impact and delamination near leading edge tape; no other findings on blade 1854

Photo 10 – Impact and delamination along leading edge on blade 1849



Photo 11 – Impact and delamination along leading edge at tip on blade 1849

Photo 12 – Scrape identified near blade root on blade 1852



Photo 13 – Both scrapes identified near the root of blade 1852

Photo 14 – Blade mounting to hub/governor



Photo 15 – Blade mounting to hub/governor

Photo 16 – Condition of blade root at connection to hub/governor; similar on all three blades



Photo 17 – Minor corrosion and pitting on internal blade shaft at weld and support; similar on all three blades

Photo 18 – Gearbox and governor with minor corrosion on shaft and centrifugal pitch



Photo 19 – Corrosion on gearbox shaft

Photo 19 – Rear of gearbox enclosure; presence of grease



Photo 21 – Shaft, brake, and generator

Photo 22 – Shaft at gearbox output



Photo 23 – Shaft at generator input

august 17, 2012 intertek test report no. 100413407crt · pdf filewind turbine industries,...

Documents