Reducing the Cost of Energy with Extended Validation and Certification of New-Generation Power Converters

As the wind turbine market grows, so do demands for quality and performance, particularly from critical components such as power converters on whose performance the whole turbine depends. That’s where extended validation and certification comes in…

Increased reliability and durability of these components makes wind turbines more economically viable. High quality design and extended validation methods of power converters are key to improving both reliability and durability, particularly in wind farms facing the toughest operating conditions.

Ingeteam’s new-generation power converters have undergone the toughest test scenarios and most realistic configurations, to prove in advance that the converter integrates properly with the turbine and operates correctly under the most demanding situations.

The industry needs continuous performance improvement and regulatory innovations takes this into account. Ingeteam is both on the committees that issue requirements and also makes sure it adds the latest regulatory developments at the design phase of new power conversion solutions. This also applies to the company’s manufacturing plants, meaning the certification of the converter helps certify the whole wind turbine.

The New Generation of Power Converters

To this day, DFIG converters remain the most proven, efficient and cost competitive drive train topology for onshore applications. Ingeteam’s DFIG converter series has cost-optimized products for each market and application. The grid-friendly converters include FRT, SCR and SSR features, so they can be deployed anywhere in the world and are particularly well suited to emerging markets such as India or Brazil.

The modular nature of the DFIG converters means they can customize and effectively minimize wind turbine LCoE. Ingeteam’s vast knowledge and experience has generated design processes that combine development and validation, to ensure the supply of optimized DFIG power converters in the market for high power applications in the range of 6 to 8 MW.

Because of the application’s particularities, grid integration is one of the most sensitive elements to keep the technology competitive and reliable while increasing the turbines’ rated power. DFIG generators and the core components of the converter are key factors that ensure a robust and reliable solution regarding the various grid events that could occur, such as harmonic fulfilment, FRT, weak grids or SSR.

Managing such events in virtually all locations is a central added-value for Ingeteam, with a high-quality model correlation that analyses any event or location that could arise.

The Power of Validations

As a critical wind turbine component, Ingeteam’s new-generation power converters must meet the highest quality requirements for wind turbine performance is dependent upon them. Ingeteam’s new power conversion solutions have passed all required tests, verifying the correct performance and the highest level of safety.

Within this validation process, a large number of tests are focused on the assessment of energy and temperature hazards. For example, functional tests assess the behaviour of the converter in the event of failure of a cooling system or insulation components, simulating these failures or in temperature rise tests. Also, mechanical tests such as IP degree, corrosion, impact, or vibration also form part of the validation.

Based on its experience in the wind turbine market, Ingeteam believes an extended validation of power converters is appropriate to optimize the design and minimize any potential issues that may arise during the integration of the component within the wind turbine.

The objective of this extended process of validation can be summarized as follows:

- To identify design improvements or detect any design failures of the converter at the earliest stage of development, minimizing subsequent design and manufacturing costs due to modifications.

- To test the converter under the most realistic conditions to validate the design under all possible scenarios and to verify it complies with requirements. The more accurate the test, the greater the reliability of the results.

To achieve this, Ingeteam carries out four types of test to provide accurate data about the behaviour of its converters when installed onsite:

- Combination tests in full-scale test benches.

- Extreme climatic condition tests.

- Extreme mechanical condition tests.

- Electromagnetic compatibility tests.

The Power of Certification

Another cornerstone of Ingeteam’s design process is certification. Achieving the combined requirements of maximum durability and reliability with cost-optimization is essential, but Ingeteam understands that different international standards can present a barrier for wind turbine installation. So, Ingeteam considers the strictest international standards for all its designs.

Ingeteam participates in the committees that issue these requirements and thus it stays up to date of the latest regulatory innovations and implements them from the design phase of the converter.

Being proactive in regulatory demands leads to the improvement of new converter designs and avoids late modifications. Any new design within the company integrates the strictest standards for all the applicable marks and labels including CE, UL or DNV-GL.

This approach is not only applied to product design, but also the manufacture of the products in its plants. For that purpose, the plants are certified for the manufacture of any component and marked with the main wind mark labels. These certifications confirm international compliance and avoid project delays due to any marking regulations and barriers. In addition, they facilitate the certification process of the wind turbine.

Ingeteam has already certified its plants for power converter within DNV-GL and UL scopes, and in addition has been trained for APQP4Wind.

The Benefits in an Instant

Extended validation of Ingeteam’s new generation of power converters confirms their operational performance under the most severe conditions. The use of fullscale test benches for integration assessment and climatic behaviour evaluation are key to optimize the design and detect potential improvements at an early stage. The information obtained from the tests assures the optimization of the design and guarantees that the converter is going to operate properly in the field.

The incorporation of the latest and most stringent regulatory requirements at the design phase and also in the certification of the manufacturing for plant, allows Ingeteam to facilitate the wind turbine certification process, wherever the geographical location, thereby reducing the project time-to-market and saving costs throughout the development and validation design processes.

Thanks to extended validation and certification, Ingeteam’s new products deliver the best onsite value for money.

 - Ion Etxarri, R&D Quality & Innovation Manager, Ingeteam Wind Energy