Revolutionizing offshore wind farm maintenance: the power of wireless connectivity

The offshore wind energy sector is rapidly expanding, with pioneering nations like the UK, Germany, and the Netherlands, followed by China leading the world with an impressive 23.9 GW offshore wind energy production capacity. Recognizing its potential, the United States, under President Biden’s leadership, has committed to constructing 30 GW of offshore wind projects by 2030, a move that could power more than 10 million homes with clean energy. Brazil also joins the ranks with an ambitious plan for 72.2 GW capacity, second only to the UK’s planned additional 78.5 GW.

Offshore wind power offers distinct advantages, including consistent high wind speeds unobstructed by terrain or buildings, resulting in reliable energy output. However, this comes with significant costs. The harsh marine environment exposes turbines to corrosion and oxidation, leading to higher risks of damage. Repairing offshore turbines is not only more complex but also more expensive and hazardous compared to onshore wind. Consequently, offshore wind production costs exceed those of solar or onshore wind, with floating turbines costing $133 per megawatt hour and fixed-bottom turbines at $78 per megawatt hour, compared to $34 per megawatt hour for onshore wind.

We firmly believe that satellite Internet of Things (IoT) technology holds the key to addressing these challenges and ushering in a new era of efficiency and safety. Satellite IoT has the potential to reduce production costs and enhance worker safety in offshore wind energy. In the following sections, we will explore the transformative role that satellite IoT can play in this vital industry.

Reducing costs: the solution lies in predictive maintenance

The most effective way to cut these expenses is through predictive maintenance. Supervisory Control and Data Acquisition (SCADA) systems allow operators to watch for problems or reduced performance and use advanced data analysis to foresee maintenance needs.

Predictive tools like Condition Monitoring Systems (CMS) play a crucial role. These systems gather and study around 250 physical data points, such as torque and force measurements, noise patterns, electrical strain, oil quality, and main bearing health. Sensors collect this information, and then AI or machine learning make the predictions more precise while reducing false alerts as the system becomes more established and the number of installations grows.

The advantages of using CMS are easy to understand. One provider of monitoring systems asserts that 90% of developing issues are detected 5 months before they become a problem, leading to a 175% annual return on investment due to less downtime and up to a 50% decrease in urgent maintenance trips.

Predictive maintenance drives 175% annual ROI for offshore wind farms

Moreover, enhancing quality control diminishes the chances of accidents, ultimately leading to potential reductions in insurance costs.

An integral component of this procedure involves sending sensor data to the cloud and subsequently to the client’s IT system, where the data is gathered, stored, and analyzed.

Typically, sensor data is transferred via underwater cables, providing numerous advantages: it’s swift, secure, and offers cost-effective transmission of substantial data volumes. Nevertheless, wired communication does come with certain drawbacks that can be mitigated through the implementation of a wireless alternative at the same location.

Why have both wired and wireless networks in an offshore wind farm?

For those who already have a wired connection to their wind farm, integrating a wireless system as a complement is a strategic consideration. Integrating new sensors into a wireless network is far less complex than adding points to an existing legacy system. To capture essential data, you simply position your sensors where needed and activate them. This eliminates the need for extensive cabling, resulting in both time and cost savings, and expediting access to additional sensor data.

Furthermore, by establishing a dedicated wireless network for your SCADA data, you ensure independent transmission of findings, unaffected by other data sources. This real-time information empowers maintenance teams to make prompt decisions on which issues to address and when. According to Turbit, this swift action can boost output by up to 5% through faster corrective measures.

While creating a new offshore wind farm with exclusive wireless connectivity can cost as little as 10% of the wired alternative and has quicker implementation, it’s important to note that satellite and cellular connections typically involve monthly usage fees and are suitable for relatively moderate data volumes. Hence, a blend of wired and wireless setups is often explored by operators in practice.

However, introducing a wireless network isn’t always straightforward for offshore wind farms, particularly when they exceed the reach of cellular networks. While 4G/LTE services generally extend up to 12 nautical miles from the coast, wind farms can be situated as far as 43 miles offshore, resulting in a coverage gap.

This gap can be bridged with a private cellular network, offering substantial throughput and robust data security. Nevertheless, the setup process for this option can be both expensive and time-consuming.

Is satellite data transmission expensive?

The landscape of satellite data transmission has undergone a significant shift due to the emergence of new operators such as Starlink and the forthcoming Amazon Kuiper Project. This influx has led to a substantial reduction in the cost of utilizing satellite networks for data transmission. Long-standing network operators, with a track record of reliability, have diversified their offerings to remain competitive against these newcomers (read more about satellite connectivity costs).

Additionally, it’s worth noting that partnering with established network operators like Iridium and Inmarsat comes with an extra advantage. Their data transfer mechanisms hold the trust of governments and militaries across the globe. Given that wind farms qualify as critical national infrastructure and are projected to become more appealing targets for cyber-crime in the near future, having access to highly secure data transfer options carries significant importance.

Who else gains from wireless sensor data transmission?

Beyond the operations team that interprets and acts on the recommendations provided by the Condition Monitoring Systems (CMS), there’s another group that benefits from wireless sensor data and analysis: the maintenance crews. These essential individuals, often stationed on offshore support vessels (OSVs), play a pivotal role in ensuring the seamless execution of offshore projects.

The same data collected by sensors and sent via satellite to the cloud can also be transmitted to the OSVs. This direct data transfer empowers maintenance crews to efficiently prioritize tasks without waiting for instructions from onshore teams. Real-time measurements of wind, humidity, wave height, and weather patterns are crucial for the safety of these maintenance workers. This sensor data doesn’t need to be sent through the main fiber communication channel, as it is vital information chiefly for the maintenance teams.

Another satellite transceiver worth considering is the RockSTAR. This portable device can link up with wearable sensors such as heart rate and body temperature monitors. It also offers two-way messaging and an SOS feature. Utilizing the Iridium satellite network, this data can be sent to safety teams, enabling prompt interventions when necessary.

Primary, secondary, or backup communication

A crucial aspect to consider in satellite connectivity for your offshore wind farm is its value as a backup communication method in case your main connection to the turbines encounters issues. Underwater cables are susceptible to damage from trawlers, environmental factors, or even deliberate sabotage. With satellite serving as a contingency, you retain the ability to both halt or initiate turbine operations and communicate with your personnel. This instant infrastructure remains impervious to weather conditions, remains independent of terrestrial networks, and maintains a high level of security.