risk prevention in the design of wind turbines
TRANSCRIPT
Risk prevention in the design of wind turbines
Renato Alves
International Meeting on Risk Prevention in the
Wind Energy Sector
Barcelona - 12. May 2010
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Risk in the design of wind turbines
Agenda
• Development process
• Risk in the „technical“ design
• Implementation’s risk
• Technical product management
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REpower development process
Requirements Definition
Project Organization
Definition Concept
Detailed conceptand
Prototype Validation
Quality Gates (simplified)
“Technical” design
Design change?
New concepts Component development Special costumer requirements Tolerances …etc
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REpower development process
Requirements Definition
Project Organization
Definition Concept
Detailed conceptand
Prototype Validation
Quality Gates (simplified)“Technical” design
Hazard Analysis
EN 14121 -1 – Risk assessment
Hazard Analysis
EN 14121 -1 – Risk assessment
Machinery Directive 2006/42/ECElectromagnetic compatibility Directive 2004/108/EC
Safety Norms
EN 12000 -1, 2 – Safety of machineryEN 50308 – WT: Protective measuresIEC 61400 -1 – WTG systems – Safety
requirements
etc…
Safety Norms
EN 12000 -1, 2 – Safety of machineryEN 50308 – WT: Protective measuresIEC 61400 -1 – WTG systems – Safety
requirements
etc…
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REpower development process Hazard Analysis
Requirements Definition
Project Organization
Definition Concept
Detailed conceptand
Prototype Validation
Hazard AnalysisHazard Analysis
Goal: Risk evaluation and reduction
Scope:- Health and safety (mandatory)- Environment- Product - All life cycle phases: Transport, Construction….Service…etc.
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REpower development process Hazard Analysis
Identify Hazards
- Mechanical- Radiation- Radiation
etc…
Identify Hazards
- Mechanical- Radiation- Radiation
etc…
Evaluaterisk
-Severity-Probability
Evaluaterisk
-Severity-Probability
Risk Reduction
- Elimination of hazards
- Risk reduction- Personal protection
etc…
Risk Reduction
- Elimination of hazards
- Risk reduction- Personal protection
etc…
Define Limits
- Functions- Uses
Define Limits
- Functions- Uses
• Several tools for risk evaluation (risk graph, risk matrix, etc…)
„There is no such thing as a perfect design“
Acceptable risk
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REpower development process Hazard Analysis - Example
IdentifyHazardsIdentifyHazards
Evaluaterisk
Evaluaterisk
RiskReduction
RiskReduction
DefineLimitsDefineLimits
Acess to hub- Acess door
- Redundant warnings
Helicopter deck (drop / pick up operations)
- 360° Metal guards
Pitch system (total shutdown)
- Fail safe
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„Real“ risk in the design phase
Wind industry in Germany 2009
Accidents Root cause*
TOP Analysis• Technical• Organization• Personal
• Wind Industry only 5% have „pure“ technical causes (not necessarily „design“)
Real risk is not in the design itself but in its implementation
* Frank Jordan, BGETEM “Arbeitssicherheit in Windenergieanlagen“ - 09.03.2010
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From theory to the field…
Requirements Definition
Project Organization
Definition Concept
Detailed conceptand
Prototype Validation
Projectorganisation
Requirements impact
Tasks coordination
Series release
Serial Implementation
Goals: • „REpower” preparation for the new design• Internal costumer from design change
New concepts Component development Special costumer requirements Tolerances …etc
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Europe Asia & Australia
From theory to the field… Company preparation ?
Projectorganisation
Requirementsimpact
Tasks coordination
Series release
Serial Implementation
Company preparation → No surprises
Project Management
Logistics
On-site Management
Service
Quality (APQP)
Sales & Marketing
Production
H&S Suppliers Human Resources etc…
North America
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From theory to the field… Internal Costumer ?
Optimization andChange coordination
Change management
Product monitoring
Serial Implementation
Development process
MM 3.XM 5M/6M
Technical Product Management
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Product Optimization
Change management
Project Management
On-site Management
QualityProduction Service
Suppliers
Technical management
H&S
Near Misses
Risk Warnings
Theoretical Know how
Practical Know how
LogisticsCostumers
Development process
Serial Implementation
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Offshore Optimization
• Less exposure time (global construction)• One less high risk procedure
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Summary
Design Risk „Technical“ design Risk
Design Implementation Risk
„Daily“ feedback
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