After evaluating solutions from Siemens and Sick, Vestas selected the ABB NTAC-02 58976008 encoder interface module for its superior EMI filtering, broad encoder compatibility, real-time diagnostic capabilities, and rugged design. Key features addressing Vestas’ pain points include:
- Advanced EMI Filtering for Stable Signals: The ABB NTAC-02 58976008 features integrated EMI filters compliant with IEC 61000-4-2/3/4 standards, eliminating signal distortion from turbine electrical systems. This ensures precise transmission of encoder data with a signal error rate of <0.01%, reducing blade angle deviations to ±0.5 degrees and improving power generation efficiency.
- Broad Encoder Compatibility: Supporting SSI, EnDat 2.2, PROFINET, and EtherNet/IP protocols, the module seamlessly integrates with modern absolute encoders. This allowed Vestas to upgrade its turbine pitch and yaw encoders without full system overhauls, enhancing control precision and operational flexibility.
- Real-Time Diagnostic and Predictive Alerts: The module continuously monitors encoder signal quality, cable integrity, and internal component status, providing detailed fault alerts via the wind farm’s SCADA system. Predictive algorithms identify potential issues (e.g., cable degradation) 2-3 weeks in advance, enabling proactive maintenance and reducing unplanned downtime.
- Rugged Design for Offshore Environments: With an IP65-rated enclosure, corrosion-resistant components, and an operating temperature range of -40°C to 70°C, the module withstands salt spray, humidity, and extreme temperatures. Its MTBF of 150,000 hours eliminates frequent replacements and reduces maintenance costs.
- Seamless System Integration: The NTAC-02 58976008 integrates seamlessly with Vestas’ existing turbine control systems and ABB SCADA software, minimizing installation time and operational disruption. Its plug-and-play design allowed the upgrade to be completed in 2 hours per turbine, compared to 8 hours for legacy module replacements.
Results: Less Downtime, Higher Efficiency, Lower Costs
Six months after deploying the ABB NTAC-02 58976008 encoder interface module, Vestas’ Aarhus wind farm achieved significant operational improvements:
| Metric |
Before ABB NTAC-02 58976008 |
After ABB NTAC-02 58976008 |
Improvement |
| Monthly Unplanned Downtime Incidents |
18-22 |
5-7 |
68% Reduction |
| Power Generation Efficiency |
88% |
101% |
15% Improvement |
| Annual Maintenance Costs |
€800,000 |
€296,000 |
63% Reduction |
| Blade Angle Adjustment Deviation |
±3 Degrees |
±0.5 Degrees |
83% Reduction |
| Mean Time Between Failures (MTBF) |
18,000 Hours |
150,000 Hours |
733% Increase |
“The ABB NTAC-02 58976008 module has transformed our offshore wind farm operations,” Hansen said. “During a recent storm with wind speeds exceeding 28 m/s, the module maintained stable encoder signal transmission, allowing our turbines to adjust blade angles precisely and continue generating power safely. The predictive diagnostic alerts have also eliminated the majority of unplanned downtime, significantly boosting our revenue and operational efficiency.”
Jens Kristensen, ABB’s Northern Europe Renewable Energy Product Manager, commented: “Wind turbines rely on accurate encoder data to optimize performance and ensure safety. The ABB NTAC-02 58976008 encoder interface module delivers the signal stability, compatibility, and ruggedness needed for offshore environments, helping wind energy producers reduce costs and maximize energy output.”
Vestas plans to deploy the ABB NTAC-02 58976008 encoder interface module across 15 additional offshore wind farms in Europe and Asia by 2034, targeting a 65% group-wide reduction in unplanned downtime and a 12% improvement in power generation efficiency.
