A US utility operating more than 30 GE 1.5 MW wind turbines across two wind power plants faced a common challenge confronting many wind asset owners. As turbines age, operators must continue to meet increasingly demanding grid code compliance while maintaining reliable and cost-effective operations.
"The utility sought a solution that would allow continued operation of its turbines while providing full control of the converter and maintaining regulatory grid compliance. Repowering offered a more cost-effective alternative to replacing major turbine components or investing in entirely new assets," says Kim Wichmann-Hansen, President of KK Group US.
Retrofitting legacy converter controls with an upgraded converter controller KK Group supported the utility by retrofitting the turbines' legacy converter control systems with its upgraded CMC1 Converter Controller .
The latest version of the CMC1 combines enhanced hardware and software capabilities, enabling it to replace legacy converter controllers across a wide range of turbine platforms. Using interface cards, KK Group can adapt the CMC1 for integration with a broader range of converter systems, helping turbine operators meet current grid requirements while extending asset lifetimes.
The solution is further supported by qualification and testing in KK Group's advanced Hardware-in-the-Loop (HIL) environment, where controller performance and grid compliance functionality can be validated before deployment.
For this project, the upgraded control solution supports compliance with US fault ride-through requirements while providing the flexibility needed to address evolving grid compliance.
Extending asset lifetime through a cost-effective path to compliance By replacing the existing converter controllers with KK Group's upgraded solution, the utility gains a practical alternative to full turbine replacement.
Converter controller retrofit enables:
"By replacing the existing converter controllers with KK Group's upgraded control solution, the utility is better positioned to maintain compliance with evolving grid requirements while extending the operational life of its wind assets," says Kim Wichmann-Hansen.
The project illustrates how targeted converter retrofits can help wind asset owners maximize the value of existing infrastructure through partial repowering. With more than 80,000 wind turbines installed across North America and an estimated 30,000 facing similar challenges related to aging control systems, grid compliance, and lifecycle extension, converter controller retrofits represent a significant opportunity for operators seeking to maximize returns on existing investments.
With converter control retrofits, we help modernize legacy wind turbines, maintain grid compliance, and extend operational lifetime.