Acoustic imaging technology provides a critical early warning mechanism for detecting potential issues in wind turbines, helping keep them operational and efficient.
Governments consider a range of complex factors when sourcing energy, including logistical, financial, environmental, and geopolitical concerns. These elements have driven the widespread growth of wind turbines globally, with geopolitical and environmental factors playing a particularly significant role.
The global expansion of wind energy
In 2023, the global wind energy sector saw an unprecedented addition of 117 gigawatts in new capacity, marking a 50% increase over the previous year. This surge has pushed total global wind capacity past 1,000 gigawatts. The countries at the forefront of these installations included China, the United States, Germany, and India.
Predominantly land-based, wind turbines make up the majority of this capacity, with offshore facilities accounting for 7%
Predominantly land-based, wind turbines make up the majority of this capacity, with offshore facilities accounting for 7%. However, offshore wind energy is expanding rapidly and is projected to become a more significant contributor as more nations invest in this evolving technology.
The wind energy sector is expected to maintain its growth momentum, with projections by the Global Wind Energy Council forecasting a compound annual growth rate of 8.8%. The offshore segment, characterised by stronger and more reliable wind conditions, is anticipated to increase tenfold by 2030, underscoring the explosive growth within the sector.
Challenges in maintaining turbines
Wind turbines, often sited in remote and hard-to-access locations, present unique logistical challenges for construction and maintenance, especially for offshore sites. Even land-based turbines located in isolated mountainous areas designed to capture maximum wind can pose difficulties for maintenance teams.
Within the turbine structure, the nacelle—which houses critical components such as the gearbox—must be accessed through a confined tower space, making maintenance and replacement of heavy components cumbersome. It is, therefore, crucial for wind farm operators to adopt measures that enhance nacelle component reliability and durability.
Monitoring key components
A key component in wind turbines is the gearbox, which is crucial for translating the slower rotational speed of the blades to a higher speed suitable for electricity generation.
These systems, containing helical gears and multiple bearings, are not only complex but also costly
Planetary gearbox systems, valued for their efficiency, are common due to their ability to enhance speed from the shaft. These systems, containing helical gears and multiple bearings, are not only complex but also costly.
Failure of these components could result in significant expenses, not just for parts replacement, but also due to the resulting turbine downtime and logistical hurdles in obtaining replacement parts. Hence, proactive monitoring to facilitate early detection of issues is vital. It allows operators to tackle problems before they worsen, thereby reducing downtime and prolonging the turbine's operational life.
Acoustic imaging as a preventative tool
Flir has launched the Si2-Series of advanced acoustic imaging cameras, engineered to identify unusual sounds indicative of early bearing failure. These portable, unobtrusive cameras can detect sounds from a distance, ensuring operator safety by facilitating inspections without necessitating operational shutdowns.
The Flir Si2-Series cameras boast a 12 MP system that captures sound and displays it on a 5-inch, 1280 × 750 high-definition colour screen, delivering clear, real-time feedback.
Designed to function as an effective early warning system for preventative maintenance, these advanced devices not only identify anomalies in bearings and gearboxes but also locate leaks in compressed air or gas systems and detect partial discharges in electrical systems. This capability not only leads to cost savings but also promotes health and safety in potentially dangerous settings.
Acoustic imaging offers a powerful early warning solution, enabling operators to detect issues before they escalate and keep turbines running efficiently.
For any government, sourcing energy involves complex decisions that extend beyond logistics, finance, and environmental considerations to include geopolitical factors. While all of these elements have influenced the rapid expansion of wind turbines worldwide, environmental and geopolitical concerns have been particularly instrumental in driving their significant growth.
The global rise of wind energy
In 2023 the global wind industry installed a record 117 gigawatts of new capacity, a 50% increase compared to the previous year. This surge brought the total global wind capacity to over 1,000 gigawatts. China led the way in new installations, followed by the United States, Germany and India. The vast majority of wind turbines are land based, with offshore making up the remaining 7%. However, offshore is experiencing faster growth and is expected to play a more significant role in the future as more countries develop and invest in the new technology.
Looking to the future, the wind energy sector is expected to continue its growth trajectory, with an anticipated compound average growth rate of 8.8% according to the Global Wind Energy Council. Offshore wind capacity, where stronger and more consistent winds are experienced, is expected to grow tenfold from its current level by 2030, exemplifying the sector’s staggering growth.
Challenges in turbine maintenance
The very nature of wind capture means that wind turbines are usually located in remote, hard the reach areas. Offshore windfarms clearly pose logistical challenges both in terms of construction and maintenance, but even land-based turbines often create real challenges for maintenance crews when positioned in remote mountainous terrain where wind capture is maximised.
Maintenance logistics even within the turbine itself can be a challenge. The nacelle, which houses the gearbox must be accessed via the tower with very limited space to move around. Inserting heavy components and lubricating oil into the nacelle is often difficult. For this reason, any measure that enhances the durability and reliability of key nacelle components is highly valuable to wind farm operators.
Monitoring of critical components
One of the critical components of a wind turbine is the gearbox. It is responsible for increasing the rotational speed from the blade shaft to the electrical generator, decreasing torque and increasing speed. Many designs incorporate planetary gearbox systems, given the efficiency of these systems to increase speed from the shaft. Containing an array of helical gears and multiple bearings these gearboxes are both intricate and expensive.
Failure can prove extremely expensive both in terms of replacing components, but also in turbine downtime, as logistical challenges of getting replacement parts often proves difficult. For these reasons, proactive condition monitoring of critical components is essential. Early detection of potential issues allows operators to address problems before they escalate, reducing costly downtime and extending the lifespan of the turbine.
Acoustic imaging as an effective early warning system
Flir have introduced a series of advanced acoustic imaging cameras capable of detecting abnormal sounds that occur when a bearing is showing early signs of failure. These handheld cameras are non-obtrusive and can pick up sounds from a significant distance, keeping the operator safe and allowing for inspections without halting operations. The Flir Si2-Series features a 12 MP camera that captures sound, and the signal is displayed on a 5-inch, 1280 × 750 high-definition colour screen providing clear, concise, real-time results.
These lightweight, cutting-edge devices are designed to provide an early warning system for preventative maintenance. Detecting abnormalities in bearings and gearbox systems is just one of their many applications. They can also identify leaks in compressed air or gas systems and detect partial discharge in electrical systems, offering not only significant cost savings but also ensuring health and safety in potentially hazardous environments.
