condition-based maintenance and inspection: key topic to ... · unplanned shutdown € 13.000,00...

Condition-based maintenance and inspection: key topic to ensure availability of your turbines

AGENDA

• Wind turbines inspection’s : are they really important ?

– What is the purpose of these ? • Main purpose• Warranty contracts

– Which intervals ? • EOW inspection’s• Troubleshooting• Periodical inspection

– What is the scope of the inspection ?• Scope and Skills• Deep inspection on critical components

• Achieve availability targets through online monitoring and planning/scheduling– CBA on Condition monitoring system– Example of planning and scheduling integration by CMMS implementation

• Question’s

What is the purpose of inspections ?

• Main purpose :In view of high investment and operational costs, economical operation of turbines is absolutely necessary, which means that downtime must be minimized by :

– Checking the quality and performance of the turbines

– Determining the current technical status of the components

– Detecting and describing initial damage

– Helping to avoid secondary damaged to early detection

And all the 20 year design-life long.

What is the purpose of inspections ?

• Whatever the maintenance/warranty contract :

Attempting to get the truth on the assets long term performance not only reduces :

- the revenue made by the Turbine, but may also be

- reducing the life time of the Turbine

As the production of the Wind Turbines is dependent on a variable resource,

Analysing/Optimizing/Ensuring the Turbine is being

Managed/Maintained/Operated

is highly recommended.

Which intervals ?

Which intervals ?

• End of warranty inspection’s :

– Suggested process :

1. Confirm the date on which the warranty expires (claim deadline)

2. Complete the tender/scope of inspection/selection 10-9 months before

EOW period

3. Complete the inspections at least 3 months before EOW period

4. Estimate the cost of repair (parts, downtime, cranes)

5. Sort the list of findings and characterize (e.g. high, medium or low)

Which intervals ?

• End of warranty inspection’s :

– Suggested process :

6. Schedule a meeting with the OEM and share the list of findings

7. Work through each item by individual turbine with close action and

dates. Finalise the meeting agreement and ask a formal notification of

recognition

8. Items not agreed : share the inspection report. After discussion, the

issue should close, if not, proceed to a formal claim

9. Submit a Formal claim and append the original list of Items and the

EOW inspection reports

Which intervals ?

• Troubleshooting:

– Right technology for the right issue :

Measure the real state of the component to take good decision

Example :

Metal particules on the gearbox filter detected by technician

• Root cause analysis :

– Method : Combine vibration/oil analysis/borescope inspection to ensure a complete diagnosis

– Objectives :

» Plan and schedule the maintenance in appropriate period

» Limit the downtime and recurrent failure

• Final observation : Poor oil quality and bearing fault on the oil pump

• Corrective actions : flushing and replacing bearing pump

• Preventive actions : Validate oil type with the OEM and oil sampling(2x/year)

Which intervals ?

• Periodic inspection’s :

The Expert consulting committee of the German Wind Energy association guidelines

describes intervals has to comply with the installed capacity of turbines :

Wind turbine less than 300 Kw Every 4 years

Wind turbine from 300 to 1500 kW Every 2 years

Wind turbine above 1500 kW Annually

What is the scope of the inspection?

• Sub-divide the project into separate disciplines :– Rotor blades

– Drive train

– General inspection

– Performance analysis

– Safety checks

– Critical assets

• Options to performing

– Self-performing

– 3rd party specialist

– Self-performing mixed with 3rd party specialist

Balancing cost over quality


• Basic/safety skills and requirements:

– Recognized working at heights certified training

– Risk assessments and method statements

– PPE

– Electrical certificate

– Operation/maintenance manual & experience


• Specialist skills/norm/tools


• Deep inspection for critical components– Standard scope : Focus on major component

• Visual inspection on the full turbine (internal & external)

• Spectral vibration analysis– Kinematic data’s

– At least 8 channels synchronous analyzer

– Alarm levels fixed following VDI 3834 norm

– ISO VIB 2 certified specialist

• Borescope inspection

• Oil analysis (hydraulic unit, gearbox)

• Laser coupling alignment

• IR thermography

• Optional : Grease analysis (Blade/main bearings)

• Optional : electrical measurment

Combined analysis = High quality diagnosis


• Deep inspection for critical components

– Modular scope : Failure mode and effect analysis

• Type of the turbine (splitted component)

• Event list/alarms

• Failure rate and downtime

• Severity x Occurrence x detection = Risk priority number

Continuous improvement : Appropriate maintenance plan,

Inventory optimization,

adjustment of preventive and predictive

maintenance tasks

AGENDA






• Question’s

Achieve availability targets through vibration online monitoring

Context :

We have listed all costs in links with :

• A major failure (crane mobilization)

• A minor failure (maintenance in nacelle)

for each mechanical component of the wind turbine.

Each cost indicated refers to a real case study for

a wind farm of 5 turbines of 1.5 MW

after 10 years of operation.

What are the benefit to predict failure on a main bearing by a CMS ?

Without CMS :Unplanned

Planned maintenance thanks to CMS

Main bearing Major Failure Spare parts € 25.000,00 € 25.000,00 Labor

(5000 €/D) € 35.000,00 € 33.950,00 -3% discount

Crane € 20.000,00 € 19.400,00 -3% discount

Looses due to unplanned shutdown € 13.000,00 € -

13 Days to plan

Totat cost € 93.000,00 € 78.350,00

Benefit on the scheduling € 14.650,00

Remark : No Minor failure regarding a main bearing replacement

Achieve availability targets through online monitoring


What are the benefit to predict a MAJOR failure on a wind turbine gearbox by a CMS ?



Gearbox Major Failure Spare parts € 150.000,00 € 150.000,00

Labor(5000 €/D) € 50.000,00 € 48.500,00

-3% discount

Crane € 20.000,00 € 19.400,00 -3% discount


13 Days to plan

Totat cost € 233.000,00 € 217.900,00



What are the benefit to predict a MINOR failure on a wind turbine gearbox by a CMS ?



Gearbox Minor failure Spare parts € 8.000,00 € 8.000,00 Labor

(5000 €/D) € 6.000,00 € 5.820,00 -3% discount

Crane € - € --3% discount


4 Days to plan

Totat cost € 18.000,00 € 13.820,00



What are the benefit to predict a MINOR failure on a wind turbine generator by a CMS ?



GeneratorMinor failure DE

bearing Spare parts € 5.000,00 € 5.000,00

Labor(5000 €/D) € 5.000,00 € 4.850,00

-3% discount



4 Days to plan

Totat cost € 14.000,00 € 9.850,00



What are the benefit to predict a MINOR failure on a wind turbine generator by a CMS ?



GeneratorMinor failureNDE bearing Spare parts € 5.000,00 € 5.000,00

Labor(5000 €/D) € 5.000,00 € 4.850,00

-3% discount



4 Days to plan

Totat cost € 14.000,00 € 9.850,00



Maintenance coste for the first 10 years of maintenance contract (5 Wtg’s – 1.5 MW)Without CMS :

UnplannedPlanned maintenance

thanks to CMSBenefit of the CMS

Main bearing

Number of major failure 2 2

Cost of major failure € 90.000,00 € 78.350,00

Number of minor failure 0 0

Cost of minor failure € - € -

Total cost € 180.000,00 € 156.700,00 € 23.300,00

GEARBOX

Number of major failure 1,5 1

Cost of major failure € 233.000,00 € 217.900,00

Number of minor failure 3 2

Cost of minor failure € 18.000,00 € 13.820,00

Total cost € 403.500,00 € 245.540,00 € 157.960,00

GENERATOR

Number of minor failure (DE) 2 2

Cost of minor failure (DE) € 14.000,00 € 9.850,00

Number of minor failure (NDE) 2 2

Cost of minor failure (NDE) € 14.000,00 € 9.850,00

Total cost € 56.000,00 € 39.400,00 € 16.600,00

Typical paint-points of the customer : Cost Benefit Analysis on a wind farm (5 wtg’s 1.5Mw) during the 10

first years of maintenance contract

CMS Cost

Without CMS CMS implementation

Hardware € -

Vibration follow-up + quarterly analysis € -

Average Cost for 5 WTG’s(Hardware + follow-up)

€ - € 75.000,00

Total cost by strategy € 639.500,00 € 441.640,00

Benefit on the prediction of fault € 197.860,00

Benefit on the avoiding downtime € 63.360,00

ROI 1,64

Spans (mounths) 22,74


Vibration online monitoring : Wind energy application :

• Multi synchronous channels (accelerometers, tachometers) for the best online monitoring (Wired)

• Possible integration of Amps Clamps, T°c• Automatic and continuous defaults detectionby frequency bands • Alarm fixed regarding VDI Norm 3834 (Onshore WTG under 3 MW) and historic data base• Integration of fault frequencies(DB Wind already existing)• Remote connexion through 3G/Ethernet TCP IP• Automatic Alarm by SMS notification• Low speed detection, order tracking• Detected defaults checked by our certified engineers ISO 18436 ISO L2• Periodical diagnosis by our engineers, even without alert• Multi-technologies integration report (services, CMS)

AGENDA






• Question’s

Achieve availability targets throughplanning and scheduling by CMMS

CMMS implementation : SCOPE on 61 E70 Enercon WTG (Italy)1) Walkthrough:

Hierarchical structure based on ISO 14224Division of categories (parts)Define a code/categoryCollect analytical from SCADA and operational manualCollect analytical data from the substation

2) Document management:Upload all the documentation on the CMMS manuals, details, etc…

3) Maintenance planOptimal frequency of maintenance actionSkills/Certificates requiredNumber of technician requiredEstimated duration of the jobClassification typology of intervention Localisation of the assetEdition of work order

4) Warehouse implementationTools and spare parts

5) KPI implementation for the continuous improvement6) Training on the CMMS

http://www.windconditionmonitoring.eu

Thanks for your attention

condition-based maintenance and inspection: key topic to ... · unplanned shutdown € 13.000,00...

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