Contributed by Jacim Jacimovic, Global Product Manager, ABB Motion
In the race to achieve clean air and low carbon future, the transition to renewable energy has become of the utmost importance. Wind energy has emerged as a frontrunner in offering sustainable energy solution. According to the International Renewable Energy Agency (IRENA), wind power has the potential to supply more than one-third of global power demand (35%) and could contribute nearly one-quarter of the annual global CO2 emission reductions needed by 2050.
However, as we celebrate the rapid growth of wind farms globally, we face a looming challenge that threatens to undermine the industry’s progress. Today, nearly half of all installed wind turbines have been operational for 15 to 20 years, entering a critical phase where performance decline becomes increasingly evident.
The implications of this ageing infrastructure are significant. As turbines grow older, their energy production diminishes, unplanned outages become more frequent, and downtime increases. These factors collectively contribute to a substantial rise in operating costs for wind farms. Moreover, the industry faces additional pressure from evolving grid codes and increasingly stringent performance requirements introduced annually, making it difficult for older turbines to remain compliant.
The scale of this issue is illustrated by the emergence of “wind graveyards” in locations such as Sweetwater, Texas. These sites serve as a reminder of the environmental and economic costs associated with premature turbine retirement. The pursuit of clean energy is proving to require more investment than initially anticipated due to wear over time – a cost ultimately borne by consumers and taxpayers.
Replacing or upgrading these aged turbines with new ones might seem like an obvious solution. However, this approach would create an enormous waste disposal issue that neither the industry nor state regulators are adequately prepared to address. It’s clear that a more sustainable solution is needed – one that balances environmental concerns with economic viability.
Fortunately, advanced technologies are opening a path to reduce maintenance costs and extend the lifetime of wind turbines. This approach not only addresses the immediate challenges but also aligns with the industry’s broader trends towards increased efficiency and cost-effectiveness. In fact, the wind energy sector has already demonstrated remarkable progress in this direction. Onshore wind energy costs have decreased by an impressive 68% over the past decade, facilitating a fourfold growth in construction from 44 GW of new installations in 2013 to 140 GW in 2023. Similarly, offshore wind energy has seen a 59% reduction in costs and an eleven-fold increase in new construction over the same period.1
The solution lies in modernization and lifecycle extension strategies, often via small software updates. By focusing on key components such as converter controllers and power electronics, using innovative technology such as energy efficient drives and motors, the lifespan of wind turbines can be significantly extended while improving their performance. If done right, this approach can effectively double the lifespan of the converter and, by extension, the entire wind turbine.
The combination of new control software and improved semiconductors enables the optimization of input and output power factor profiles, increasing the produced electric power up to 10 %. This boosts energy production and helps turbines meet evolving grid requirements, ensuring their continued relevance in the changing energy landscape.
Moreover, modernizing the converter supports the deployment of advanced condition monitoring systems. These systems allow for real-time assessment of component health, facilitating predictive maintenance strategies. This proactive approach helps prevent failures, reduces downtime, and further extends the operational life of wind turbines, increasing reliability as well as annual energy production.
By focusing on converter modernization, the wind industry can increase power output by up to 5% or achieve savings of 35% in electricity costs. These improvements in system efficiency have a double benefit, both enhancing the economic viability of existing wind farms as well contributing to the broader goals of renewable energy adoption and environmental conservation.
The next step for wind energy is not just about building new turbines; it’s about maximizing the potential of the existing infrastructure. Through modernization and lifecycle extension, we can breathe new life into ageing wind turbines, ensuring they continue to generate clean energy for years to come. This approach not only makes economic sense but also represents a more sustainable and responsible way to manage our renewable energy resources. Together, we can ensure that wind energy remains a powerful and sustainable force in our global energy mix, driving us towards a cleaner, greener future for the generations to come.