last days of suppliers hegemony: customer driven market has come athens, march 1 st, 2006 ester...

Last days of suppliers hegemony: customer driven market has come

Athens, March 1st, 2006

Ester CámaraOperations Manager

Iberdrola Renewables Energies

IBERDROLA RENEWABLES ENERGIES 2March 1st, 2006

Over the last years wind energy sector has experienced a rapid evolution

• Spain new objective: To double actual installed capacity up to 20.000 MW by year 2010.

SPAIN Installed capacity (MW)

0

5.000

10.000

15.000

20.000

25.000

2003 2004 2005 … e2010

+100%

Europe new objective:75.000 MW by year 2010


One year in advance, Iberdrola has accomplished its first strategic plan

IBERDROLA Installed capacity (MW)

01.000

2.0003.000

4.0005.000

6.0007.000

2003 2004 2005 … e2008

Spain Other

Strategic plan 02-06 succeded in 2005

New objective5.800


Iberdrola #1 wind energy world company

Iberdrola presence


4.372 wind turbine generators as of December 2005

WTG Provider

Power capacity

(kW)#

GAMESA 660 1.429

GAMESA 850 1.845

GAMESA 2.000 337

GE 750 99

GE 1.500 290

SIEMENS 600 203

SIEMENS 1.300 55

ENERCON 800 62

VESTAS 660 13

VESTAS 2.000 9

ECOTECNIA 1.670 30

TOTAL 4.372

GAMESA GE SIEMENS OTHER


Iberdrola is applying its own professional production management model to wind energy

Maximize economic performance of every wind farm

during the extension of its lifetime

Starting point

Production Management Model

Main goal Iberdrola’s 100 years

utility culture Wide O&M expertise:

Hydroelectric Gas combine cycles Nuclear Renewables Fuel oil Coal Cogeneration

• Iberdrola doesn’t develop a wind farm to sell it

• Iberdrola develops to create value

Systems and procedures

Strategy

Organization & functions

“Dominate technology and key management

factors”


DOMINA project: Development of a Production and Maintenance Management System

Objective 1:

Maximize economic

performance of wind

farms

ASSET MANAGEMENT

MAINTENANCE MANAGEMENT

OPERATING EXPERIENCE FEEDBACK

PRODUCTION MANAGEMENT

• Collection of every asset information in an homogeneous way

• Control of changes in the asset

• Analysis of incidents and identification of root causes

• Definition of WTG design modifications to increase its reliability

• Quantification of unproduced energy• Identification of the main causes of

unproduced energy

Dominate technology

Objective 2:

• Supervision of maintenance process• Review and improvement of tasks• Achievement of an efficient maintenance cost


Communications and hardware simplified architecture

WAN

...WIND FARM A

99999999ROUTER

Local Control System

Corporate Network Access System

...WIND FARM B

99999999ROUTER

Local Control System

Corporate Network Access System

INTRANET

INTERNET

FIREWALLProduction ManagementServer

SAPMaintenance ManagementServer

CORPORATE NETWORK

ROUTER ROUTER

DOMINA SYSTEM

Retro projection screen

CENTRAL OPERATION CENTER NETWORK

ROUTER ROUTER

SCADA #1HDB #2

SCADA #2HDB #1

IBERDROLA CENTRAL OPERATION CENTER


DOMINA: Asset management

SystemsSystems

Wind farmWind farm

WTGWTG

• Starting point is capture of the physical configuration of every wind farm• Technical positions: functional positions of the wind farm to which the maintenance

works is addressed• Equipments: components that can be tracked through their serial numbers. This enables

history saving, traceability and warranty management• Clasification system with valued features• Documentation associated to every specific component of the asset

CodeCode DescriptionDescription

Illustra

tive


DOMINA: Maintenance management (I)

• Work order is the tool to control maintenance tasks, maintenance cost and feedback operating experience

• 4 kinds of activities: preventive maintenance, corrective maintenance, local restart, design modification

Illustra

tive


DOMINA: Maintenance management (II)

• Affected part of the object• Failure mode• Cause• Alarm presented by the WTG• Time interval the WTG hasn’t been running• Human or environtmental damages• Other relevant information

ADITIONAL INFORMATION

• Object the maintenance points to• Activity kind: Preventive, corrective,

local restart, design modification• List of tasks to be done• Materials needed: consumables, spare-

parts, etc.• Professional qualification of workers• # of hours used• Work description

BASIC INFORMATION

Only for CORRECTIVE MAINTENANCE

and LOCAL RESTARTS Enables feedback of operating

experience

WORK ORDER


DOMINA: Maintenance management (III)

Preventive Local Restarts

Design Modification

Corrective

WTG

Medium Voltage System

Substation

Civil Works

Meteorological Mast

HOURS

MATERIALS

AUXILIARY EQUIPMENT

• Work order allows appropriate control of maintenance expense


DOMINA: Production management

Causes of unavailability

• O&M people at wind farms characterize every single stop occurred, naming causes of unavailability

• Iberdrola’s own methodology to obtain production reference for every WTG every day• Automatically DOMINA obtains working parameters: unproduced energy, time intervals,

frequencies• Parameters turn into indicators that are used to control and manage production

Unproduced Energy• Gap identification for

particular time intervals• Due to unavailabilities

Pro

du

ctio

n r

efe

ren

ce

Rea

l p

rod

uc

tio

n

Unavailability 1

Unavailability 2

Unavailability 3

Unavailability 4

Unavailability 5

Maintenance

OperationTime intervals

Working parametersWorking parametersProduction indicators

Operation indicators

Maintenance indicators

Production indicators

Operation indicators

Maintenance indicators

Frequencies


DOMINA: Operating Experience Feedback

• With the information provided in the work order, FMEA methodology is applied to discover the root cause of main incidents

• Aiming reliability of wind farms, either maintenance or design modification is developed

1. Human or environmental damage

2. Reparation Cost

3. Production losses

Priority criteria

Root Cause Identification

Design Modification

Maintenance Standards Modification

Wind Farms RELIABILITYEco

nom

ic a

nd

lifeti

me

analy

sis

Eco

nom

ic a

nd

lifeti

me

analy

sis

FMEA

m

eth

odolg

yFM

EA

m

eth

odolg

y


Key factors to succeed

• Utility with more than 100 years of production, operation and maintenance experience

• Worldwide #1 in wind energy

• Develops wind farms to create value

• Cares about assets lifetime

• Has its own technical specification for WTG main components

• Works close together with WTG providers to obtain the best technology

• Works close together with maintenance contractors to obtain the best maintenance standards

• Feedback technology partners to improve wind technology and make it more reliable

last days of suppliers hegemony: customer driven market has come athens, march 1 st, 2006 ester...

Documents

corrective maintenance

preventive maintenance

maintenance tasks

maintenance works

wind farmtechnical positions

wind turbine generators

years wind energy sector

domina project