The global wind industry is set to experience rapid growth and transformation over the next few years as governments ramp up their efforts to hit net zero. According to the Global Wind Energy Council’s latest statistics, the wind industry is set to triple its growth from 117GW in 2023 to at least 320GW by 2030.
While the future is bright, the surge in wind farms has led to a significant increase in fire-related risks, driven by an increase in turbine size, new manufacturers, and co-located assets. Local communities and regulators are also becoming increasingly concerned over fire risks at wind farms – further compounding the challenge facing developers.
For the industry to realise its full potential, wind developers and their engineering teams will need to take urgent steps to protect against rising fire risks. What’s driving the increase in fire risks?
A number of factors have driven the increase in fire-related risks within the wind industry:
1. Ageing wind assets – When the wind industry first took off, fire safety was often an afterthought. As a result, a whopping 75-80 per cent of operational wind turbines do not have fire suppression systems in place, and fire risks increase by a significant 30 per cent for wind assets aged between 5-10 years, according to data from Wind Power Engineering.
2. Larger turbines – The race to build bigger, more efficient wind farms has led to an increase in turbine size. In 2000, 2MW turbines were the standard, but by 2030, 20MW+ turbines could be in place, and a number already are. For example, Mingyang Smart Energy recently announced that it had installed the world’s largest turbine at a wind farm in Hainan, China, which can deliver up to 20MW. The complexity of these massive turbines has made them more susceptible to fires, and steps must be taken to protect them.
3. New manufacturers – The increase in wind farms has led to several new turbine manufacturers entering the market. Their entrance is welcome as it creates more competition and innovation within the market, but it also creates more risks as the new turbines are often untested and unproven. In addition, systems like fire suppression may need to be customised for newer designs.
4. Rise in co-located assets – In 2023, co-located projects – which combine solar, wind, battery and other renewable technologies together – increased by 90 per cent. This rise has led to a significant increase in fire risks due to the additional complexity and hazards batteries introduce.
What steps should engineers take to protect against increasing fire risks?
The challenge and pressure facing wind developers may seem daunting, but there are several steps their engineering teams can take to protect wind farms against growing fire risks:
· Install fire suppression systems from the start – The easiest step is to install fire suppression systems from the outset of a project. This ensures wind farms are protected from the start and avoids expensive retrofitting projects that can cost developers between $220k-$329k in downtime loss per wind farm. It also avoids up to $11m in potential losses per turbine if a catastrophic fire occurs before fire suppression systems are in place.
· Use fire-resistant materials – Using fire-resistant materials and resins in turbine designs and manufacturing is critical to limiting the spread of fires. These materials and resins are especially important for the nacelle (that houses the key turbine mechanical components), blades and other fiberglass components.
· Avoid flammable liquids and seal key components – Limiting the use of flammable lubricants, such as traditional oils, can dramatically reduce the chance of a fire. Also, ensuring critical components, like the gearbox and generator, are well-sealed can reduce the spread, as leaking hydraulic fluids and oils can increase fire risks.
· Conduct regular maintenance – Regular inspections and maintenance of wind turbines ensures that all potential fire risks are addressed before it’s too late. Important service and maintenance items should also not be inadvertently left inside electrical cabinets or transformer spaces, as they can lead to fires.
From an industry-wide perspective, we will need to ensure that we have the engineering teams with the right skills and knowledge to protect wind farms against fire risks. The number of engineers will also need to increase by 43 per cent from around 52,000 in 2023 to almost 75,000 in 2027, according to the Global Wind Workforce Outlook 2023-2027. As a result, the industry will need to undertake comprehensive skilling and upskilling programs that equip engineers with the skills, knowledge, and insights needed to fire-proof wind farms.
The global wind industry is on the cusp of great change, but more needs to be done to mitigate the increase in fire risks and ensure all wind farms are protected. It may seem like a significant undertaking, but taking the above steps will go a long way to protecting assets and enhancing fire safety across the industry. In turn, this will help to accelerate the development of the global wind industry and enable us to meet our ambitious net zero targets.
Brian Cashion, director of engineering at Firetrace International
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