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Exploring the Causes of Power-Converter Failure in Wind Turbines based on Comprehensive Field-Data and Damage Analysis

Author

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  • Katharina Fischer

    (Fraunhofer Institute for Wind Energy Systems (Fraunhofer IWES), 30159 Hannover, Germany)

  • Karoline Pelka

    (Fraunhofer Institute for Wind Energy Systems (Fraunhofer IWES), 30159 Hannover, Germany)

  • Sebastian Puls

    (Fraunhofer Institute for Silicon Technology (Fraunhofer ISIT), 25524 Itzehoe, Germany)

  • Max-Hermann Poech

    (Fraunhofer Institute for Silicon Technology (Fraunhofer ISIT), 25524 Itzehoe, Germany)

  • Axel Mertens

    (Institute for Drive Systems and Power Electronics IAL, Leibniz University Hannover, 30167 Hannover, Germany)

  • Arne Bartschat

    (Fraunhofer Institute for Wind Energy Systems (Fraunhofer IWES), 30159 Hannover, Germany)

  • Bernd Tegtmeier

    (Fraunhofer Institute for Wind Energy Systems (Fraunhofer IWES), 30159 Hannover, Germany)

  • Christian Broer

    (Fraunhofer Institute for Wind Energy Systems (Fraunhofer IWES), 30159 Hannover, Germany)

  • Jan Wenske

    (Fraunhofer Institute for Wind Energy Systems (Fraunhofer IWES), 30159 Hannover, Germany)

Abstract

Power converters are among the most frequently failing components of wind turbines. Despite their massive economic impact, the actual causes and mechanisms underlying these failures have remained in the dark for many years. In view of this situation, a large consortium of three research institutes and 16 companies, including wind-turbine and component manufacturers, operators and maintenance-service providers has joined forces to identify the main causes and driving factors of the power-converter failures in wind turbines to create a basis for effective remedial measures. The present paper summarizes and discusses the results of this research initiative, which have been achieved through the evaluation of converter-specific failure and operating data of a large and diverse worldwide wind-turbine fleet, field measurements as well as post-mortem investigation of returned converter components. A key conclusion of the work is that the thermal-cycling induced fatigue of bond-chip contacts and die-attach solder, which is a known issue in other fields of power-electronics applications and which has been widely assumed to be the principle damage mechanisms also in wind turbines, is no relevant contributor to the observed converter failures in this application. Instead, the results indicate that environmental factors such as humidity and contamination but also design and quality issues as well as human errors play an important part in the incidence of these failures.

Suggested Citation

  • Katharina Fischer & Karoline Pelka & Sebastian Puls & Max-Hermann Poech & Axel Mertens & Arne Bartschat & Bernd Tegtmeier & Christian Broer & Jan Wenske, 2019. "Exploring the Causes of Power-Converter Failure in Wind Turbines based on Comprehensive Field-Data and Damage Analysis," Energies, MDPI, vol. 12(4), pages 1-27, February.
    • Handle: RePEc:gam:jeners:v:12:y:2019:i:4:p:593-:d:205489
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    References listed on IDEAS

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    1. Lin, Yonggang & Tu, Le & Liu, Hongwei & Li, Wei, 2016. "Fault analysis of wind turbines in China," Renewable and Sustainable Energy Reviews, Elsevier, vol. 55(C), pages 482-490.
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    Cited by:

    1. Cevasco, D. & Koukoura, S. & Kolios, A.J., 2021. "Reliability, availability, maintainability data review for the identification of trends in offshore wind energy applications," Renewable and Sustainable Energy Reviews, Elsevier, vol. 136(C).
    2. Faisal Wani & Udai Shipurkar & Jianning Dong & Henk Polinder, 2021. "Thermal Cycling in Converter IGBT Modules with Different Cooling Systems in Pitch- and Active Stall-Controlled Tidal Turbines," Energies, MDPI, vol. 14(20), pages 1-25, October.
    3. Katharina Fischer & Michael Steffes & Karoline Pelka & Bernd Tegtmeier & Martin Dörenkämper, 2021. "Humidity in Power Converters of Wind Turbines—Field Conditions and Their Relation with Failures," Energies, MDPI, vol. 14(7), pages 1-27, March.
    4. Faisal Wani & Udai Shipurkar & Jianning Dong & Henk Polinder & Antonio Jarquin-Laguna & Kaswar Mostafa & George Lavidas, 2020. "Lifetime Analysis of IGBT Power Modules in Passively Cooled Tidal Turbine Converters," Energies, MDPI, vol. 13(8), pages 1-22, April.
    5. Pawel Szczesniak, 2019. "Challenges and Design Requirements for Industrial Applications of AC/AC Power Converters without DC-Link," Energies, MDPI, vol. 12(8), pages 1-18, April.

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