ge energy effective operation and maintenance of wind turbines through use of advanced services...
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GE Energy
Effective Operation and Maintenance of Wind Turbines Through Use of Advanced Services Technologies Philippe KavafyanGE Energy February 2006Athens, Greece
2GE Energy - PhilippeKavafyan
February 2006
3-5% Wind Project IRR is allocated to risks associated with variances in energy production and cost of O&M
Unplanned ~70%
•Service Access
•Crane Cost•Material Cost•Labor Cost
••
O&M CostsA Significant Portion of COELarge Variance
Cost Variance
DecreasedAvailability
DecreasedProduction
DecreasedRevenue
Planned ~30%
Cost-of-Energy
O&MWTG, BOP & Other
… A Comprehensive O&M Strategy is Critical to Successful Project Economics
3GE Energy - PhilippeKavafyan
February 2006
O&M Cost Variability Driven By Product Reliability
• Life-cycle Reliability Has Large Impact on O&M Costs
• Planned O&M can vary from 10% to 35% of total cost
• Offshore Access … jack up barge, weather, etc. add additional cost and variance
Offshore Access
Unplanned O&M
Planned O&M
Wind Turbine Reliability
1 4X
10X
Tota
l O
&M
Cost
… Unplanned O&M Cost Significantly Impacted by Component Reliability
4GE Energy - PhilippeKavafyan
February 2006
Production Impact from Unplanned Events
… Accessibility Key to Managing Impact of Unplanned Events
Wind Turbine Availability
70
75
80
85
90
95
100
1 2 3
Event
Availab
ilit
y (
%)
Event 1: Remote Resolution
Event 2: Requires WTG visit & smallcomponent replacement
Event 3:Requires WTG visit, major component replacement w/
jack upbarge
Max Wave Height - by Month
0
1
2
3
4
JUL
AUGSE
POCT
NOV
DEC JA
NFE
BM
ARAPR
MAY
JUNW
ave H
eig
ht
(m)
AccessThreshold
Event 1
Event 3
Event 2
UnplannedDowntime
Annual Energy Production
100001050011000115001200012500130001350014000
1 2 3Event
MW
-Hrs
5GE Energy - PhilippeKavafyan
February 2006
Reduce risks to revenue & costs from turbine failures
Current
RealisticAdditional Costs after Warranty Expires
Realistic
Loss Revenue due to
Increased Wear & Tear and Failure
Rates, which results into
reducedAvailability
Revenue
Year0 20
Customer View
Customer View
Revenue
O&M Costs
$
Year0
Customer View
2
Profit
How is GE addressingthis challenge?
7GE Energy - PhilippeKavafyan
February 2006
Apply Services Best Practices
Power PlantMedical EquipmentIndustrialEquipment
Aircraft EnginesLocomotives
GE Services > 30,000 Major
Equipment Under Service Worldwide
> 100 Services-related patents
Creating New Services Technologies For ~ 20 Years
Equipment Services& Products
PerformanceOptimization
Services
SmartServices
• Equipment Support • Anomaly Detection• Condition Assessment• Diagnostics & Troubleshooting• Repairs & Upgrades
• Contract Performance• Parts Life Management• Asset Management
• Performance & Availability Guarantees
• Equipment Upgrades• Plant Energy
Management
Incr
easi
ng
Cust
om
er
Valu
e
8GE Energy - PhilippeKavafyan
February 2006
Revenue
COE
Reliability
Availability
Production
Customer Benefits
• Enhanced Offshore Equipment Designs
• Advanced Controls for Load Mgmt & Performance
• Design for Serviceability
Product Reliability (Prevention)
Service Technologies for Effective O&M
• High Quality Planned & UnplannedMaintenance
• O&M Asset Management• EHS Trained
Field Services
• 24/7 Remote Operations, Monitoringand Diagnostics
• Predictive & Condition Based Maintenance
• Contractual Services/Warranty Mgmt
Product / Customer Support
• Reliability & PerformanceModifications & Upgrades
Continuous Improvement
… Multi Pronged Service Approach Required
9GE Energy - PhilippeKavafyan
February 2006
Goal: Design turbines to deliver very high availability …. Breaks Down Rarely
Approach:
• Utilize “Design for Reliability” & Serviceability
• Extended FMEA analysis to define causal events and impacts of failures
• Physics-based Reliability Models to understand true design and operational limits
• Redundancy of selected components to reduce availability impact of failures
• Advanced Controls for Load Management & Performance enhancement
ServiceabilityProduct Reliability (Prevention)
Physics-based Models
2.00E+091.00E+090-1.0E+09-2.0E+09
140
120
100
80
60
40
20
0
Amplitude
Fre
quen
cy
Histogram of Amplitude, with Normal Curve
Extended FMEAs
Advanced Controls
10GE Energy - PhilippeKavafyan
February 2006
Goal: Increase Availability….Minimize Field Costs….Increase Customer Value
Product / Customer Support
Approach: Customer Support Centers
• 24/7 Remote Operations, Monitoring and Diagnostics
• Automated Fault Notification Wind Farm
FaultCondition
Expert“Rules” Engine
CSC(Customer
Support Center)
Auto Reset
Automated Fault Notification
Wind Farm
FaultCondition
Expert“Rules” Engine
CSC(Customer
Support Center)
Auto Reset
Automated Fault NotificationAutomated Fault Notification
CaliforniaGerman
y
Shanghai Atlanta
HQ
Support Centers
Next 21 Faults
Rest
Collective fault pitch controller
Undervoltage
Blade pitch control dev.
3 pitch controller
faults
Pitch Overrun 90°
Wind Deviation
Timeout pitch controller
Error 180: „Wind deviation“
NO
Remote Control Are the parameters 7.5 and 7.6 at the correct values?
Remote Control Log the alarm in the
Access datab ase
NO YES
END
NO
Remote Control Need further investigation
depending on the following errors
Remote Contro l Change the parameters
YES
Remote Control Is the PLC software
version recent?
YES
Remote Control Is there any of the non -resetable errors
in the turbine status?
Service Team Go on the site and change the
PLC software. Remote Control Is the status OK
in the wtg status ?
YES NO
Remote Control Further investigation is needed (snapshot ). There
might be following errors in the turbine status .
NO
Major Faults Detailed Diagnosis
Faults HandlingProcedures
Next 21 Faults
Rest
Collective fault pitch controller
Undervoltage
Blade pitch control dev.
3 pitch controller
faults
Pitch Overrun 90°
Wind Deviation
Timeout pitch controller
Next 21 Faults
Rest
Collective fault pitch controller
Undervoltage
Blade pitch control dev.
3 pitch controller
faults
Pitch Overrun 90°
Wind Deviation
Timeout pitch controller
Error 180: „Wind deviation“
NO
Remote Control Are the parameters 7.5 and 7.6 at the correct values?
Remote Control Log the alarm in the
Access datab ase
NO YES
END
NO
Remote Control Need further investigation
depending on the following errors
Remote Contro l Change the parameters
YES
Remote Control Is the PLC software
version recent?
YES
Remote Control Is there any of the non -resetable errors
in the turbine status?
Service Team Go on the site and change the
PLC software. Remote Control Is the status OK
in the wtg status ?
YES NO
Remote Control Further investigation is needed (snapshot ). There
might be following errors in the turbine status .
NO
Major Faults Detailed Diagnosis
Faults HandlingProcedures
Major Faults Detailed Diagnostics
• Expertise-based Fault Resolution
• Remote Communication Reliability
11GE Energy - PhilippeKavafyan
February 2006
Reliability-Based Preventive Maintenance Strategy
Approach: Efficient Risk Allocation
• Contractual Services/Warranty Mgmt
• Predictive & Condition Based Maintenance
• Shift Planned Maintenance to Low Wind Period
• Use Reliability Models to Drive Maintenance Intervals for Optimal Performance
• Use Site-specific Maintenance Factors to Assess Damage Accumulation
Goal: Reduce Unplanned Maintenance … Increase Production
0
0.2
0.4
0.6
0.8
0
Ac
cu
m e
qv
. da
ma
ge
IEC class IIA
Plant1Kt = 2.2
~ 2XKt = 2.2Kt = 2.2
~ 2X
-150
-100
-50
0
50
100
0.E+00 2.E+08 4.E+08 6.E+08
cycle
str
es
s,
MP
a
Damage Fraction at Hot Spot of Main Shaft
(Plant 1 vs IEC II)
Plant 1 has accumulated half the designed damage … can extend planned maintenance intervals
EXAMPLE
X
12GE Energy - PhilippeKavafyan
February 2006
0
10000
20000
30000
40000
50000
60000
70000
80000
90000
100000
Ma
y
Jun
Jul
Jul
Au
g
Se
p
Oct
No
v
De
c
Jan
Fe
b
Ma
r
Ap
r
Ma
y
Jun
Jul
Au
g
Se
p
Oct
No
v
De
c
Jan
Fe
b
Ma
r
Ap
r
tota
l n
um
ber
of
par
ticl
es
Oil change,flushing
shut down
gearboxexchange
measurement forecast
Total Cumulated Number of Metallic Particles > 200 Microns in Gearbox Oil
2005 2006
Approach: Gearbox Metallic Particle Monitoringtotal loss
of gearbox
Condition Based Maintenance
Goal: Increase Damage Predictability
planetary bearing inspection
outer ring
roller rotor side bearing
middle baring
11. Jun 04
11. Jun 04
June ‘04
roller rotor side bearing
middle bearing
Oct ‘04
rotor side bearing
Aug ‘05
13GE Energy - PhilippeKavafyan
February 2006
•Offshore Access Systems•Commissioning•Regular O&M duties•Overhaul tasks
•Access/Weather Modeling
•Jack-up Barge Logistics
•Service Friendly Equipment
•Asset Management
Offshore Field Services
Project % Wave Height > 2.0 MetersProject 1 48%Project 2 3.5%Project 3 8.1%
Goal: Effective Access System & Logistics for rapid field response
14GE Energy - PhilippeKavafyan
February 2006
Product Continuous Improvement
Approach:
• Identify Opportunities
• Fleet Reliability and Availability Metrics
Goal: Increase Reliability & Production Capability Through Modifications and Upgrades
z
y
x
Adaptive Drive Train Damper Control Upgrade
Power &Performance Uprate
Reliability Improvement
Years
Driv etrain Grid
Conv erter Pitch
Controls Others
• Fleet Faults & Root Cause Analysis
• Residual Life Prediction Tools
• Introduce Modifications and Upgrades from RCA & New Technology Development
15GE Energy - PhilippeKavafyan
February 2006
Why Services Agreement with OEM?
• More efficient risk allocation between the Owner and OEM (Original Equipment Manufacturer)
> Owner Keeps Commercial Risk (Wind Risk, Energy Pricing)
> OEM takes on Equipment & Performance Related Risks
• OEM is in the best position to manage this risk in a cost effective manner
> Design and Manufacturing expertise> Built-in incentives to maximize return on
investment for the owner – a partnership arrangement
> Benefits from new products & technology development
•Effective O&M is Critical for Reducing Project Risks
•Unplanned Maintenance Drives Variationin Cost & Loss in Production
•GE focused on developing ServicesTechnology … key to cost effectivelymanaging O&M
Summary
"Effective Operation and Maintenance of Wind TurbinesThrough Use of Advanced Services Technologies"
GE Energy
Philippe KavafyanGE Energy February 2006Athens, Greece