maximizing performance by windfarm services

M A X I M I Z I N G P E R FO R M A N C E BY W I N D FA R M S E RV I C E S

Brazil Windpower 2016 - Rio de Janeiro

1st of September 2016

Thomas Kunzmann, Managing Director

Fabricio Klein, Operations Manager Monitoring

1

M A X I M I Z I N G P E R F O R M A N C E B Y W I N D F A R M S E R V I C E SBrazil Windpower 2016, Rio de Janeiro


Company

Challenges

Permanent Monitoring and IT

Technical Inspections

Summary

AGENDA



WINDWERK IS PART OF GERMAN DGE GROUP AND HAS 20 YEARS OF EXPERIENCE IN SOUTH AMERICA AND EUROPE

20 years of international experience in Europe and South America with Renewable Energies

Activities in Germany, France, Chile and Brazil

Operations Management of 230 wind turbine generators with 300 MW

Project development >200 MW

Manufacturer independent: cooperation for example with Enercon/Wobben, Suzlon/Senvion, Vestas, GE

Application of German quality standards

Company Profile



DGE HAS COMPETENCES IN DEVELOPMENT, FINANCING AND OPERATIONS

Core competences of DGE Group

BUSINESS DIVISIONS

COMPETENCIES

REALIZEDSERVICES

DEVELOPMENT FINANCINGCOMERCIAL

MANAGEMENT

• Project Development

• Acquisition of

Projects

• > 300 MW of

acquired projects

• >200 MW of own

development in

France and Germany

• Project Financing

• Conception of Funds

• Share Capital

Acquisition

• 13 funds

• Financing volume of

500 Mi. Euro

• About 125 Mi. Euro

of collected share

capital

• Investor Relations

including Customer

Care

• Tailored Reports

• Contract Acquisition

• Contract Controlling

• 11 funds

• > 2.000 investors

OPERATIONAL MANAGEMENT

• Monitoring

• Operations Mgmt

• Performance

Analysis

• Coordination of

Maintenance

• Quality Control &

Inspections

• 15 wind farms

• > 230 WTG from GE,

Enercon/Wobben,

Suzlon/Senvion,

Vestas, Nordex

• 300 MW

• 2 solar farms with 12

MWp



WE SUPERVISION DAILY 300 MW WIND AND 12 MW SOLAR

Solar farms with 12 MWp in Germany and Chile:

Sharp: 32.000 Modules

RWE Schott Solar: 6.500 Modules

JA Solar: 4.000 Modules

SMA Inverters

Siemens Inverters

15 wind farms/230 WTG with 300 MW across Europe:

Suzlon/Senvion: 60x MD70/77

Enercon/Wobben: 70x E40, 25x E66, 17x E70

Vestas: 14x V66, 11x NM1500

General Electric: 22x TW600, 14x GEWind 1.5

Nordex-Acciona: 2x N117

Our Portfolio



Company

Challenges



Summary

AGENDA



RAPID DEVELOPMENT AND INCREASE OF COMPLEXITY OF WIND TURBINES REQUIRES SPECIALISTS

Challenges and possible consequences

Today’s machines generate 100 times as much electricity as earliest wind turbines and have a much higher complexity

Throughout their operating life wind turbines are subject to enormous stresses

Defects are not always visible and often only experts can detect them by specialized analysis

Unremedied defects can impair performance and lead to unplanned disturbances

Long downtimes can come at a high price and can turn a project negative

Full maintenance contract offer a certain protection, however do not guarantee fast reaction



OPERATIONAL MANAGEMENT OF WIND FARMS IS IMPORTANT FROM THE BEGINNING AND GETS CRITICAL AFTER 5 YEARS

How to master the challenges

Mandate constant monitoring by experienced specialists

Check clauses of operational contracts

Comission inspections at least every 4 years of operation, after 12 years every 2 years

Consider to mandate inspections one year prior to end of garantee or full maintenance contract to make demands in time

Check insurance protection and if necessary adjust to close gaps

Monitoring, inspections and maintenance are indispensable in order to continuously achieve maximum electricity yields regular



Company

Challenges



Summary

AGENDA



MONITORING ESPECIALLY IN COMBINATION WITH BASIC MAIN-TENANCE IS ADVANTAGEOUS AND HAS BECOME A GLOBAL TREND

Monitoring tasks and costs by maintenance scenario

• Take care of daily operations

• Supervise basic maintenance

• Commission preventive

measures and repairs as required

Tasks in Basic Maintenance

• Check the execution of the service

provider on a daily basis

• Close „gaps“, if any

Tasks in Full Maintenance

OPEX by Maintenance Scenario



FOR SUCCESSFUL MONITORING INTERPLAY BETWEEN KNOW HOW, NETWORK AND EFFICIENT IT SYSTEMS IS CRITICAL

Success Factors of Monitoring

• Stable and integrated IT systems

• Infrastructure needs for data storage and access

• Regular contact to manufacturers, suppliers, operators and service providers and exchange

• Experience with wind farms

• Qualification and regular training of personnel

IT

Know How

Network



In partnership with:

OUR SOLUTION FOR INTEGRATED AND PERMANENT MONITORING OF DIFFERENT BRANDS: WIS



• Communication to the power plants (WIScom / WISout)

• Automated monitoring of all power plants

• Central management of all relevant information

• Statistics & Reports

• Analysis functions

MAIN TASKS OF WISIn partnership with:



Communication Solutions:

Wind energy-

Information-System

Our central standard communicationsolution that needs no installation insidethe wind farm

Our alternative communication solutionthat has to be installed inside the windfarm

SOLUTION CAN BE USED ON OWN SERVER OR VIA CLOUD SERVICES




OLD FASHIONED AND MODERN COMMUNICATIONS CHANNELS CAN BE USED TO ACCESS DATA




Manufacturer Control/Interface Moment Status 10-Minute Day Month

AN Wind / Bonus Energy (AN Bonus) Wind Leistung Supervisor (WPS) -

Bonus Energy A/S RMS x - - -

DanControlWindMan -

WindMan Server - -

EnerconSCADA / Auto Data Request x

OPC

Gamesa SGIPE -

GE / Enron / Tacke VisuPro

MitaWPMS (AutoCall) x -

Mita Gateway

NordexNordex Control

Nordex Control 2 (NCII) -

Vestas

WindHandle - -

VestasOnline Compact - -

VestasOnline Business - -

Senvion IEC 61400-25

… …

Implemented x Not implemented - Not included

WIS OFFERS INTERFACES TO NEARLY EVERY TURBINE TYPE IN REAL TIME




• Contains approx. 100 WIS-modules

• WIS is available in 5 languages and is used Europe-

wide by 44 customers

• Approx. 7.400 WTG are managed with WIS

• Integrated mobile support (WIS2Go)

• Support of many interfaces (energy meter,

communication-interfaces, third-party solutions,

Webservices…)

WIS IS MOST RENOWED BRAND FOR MONITORING IN EUROPE




MONITORING DISCOVERS THROUGH DETAILED ANALYSIS ADDITIONAL GEARBOX DAMAGES IN 2 TURBINES

Background

One turbine in a farm of 10 WTG was shut down due to gearbox failure. Exchange is expected to take a minimum of 2 months in total .

Our Approach

Permanent Monitoring analyses the whole wind farm in detail and commisions technical inspections of all turbines.

Inspections show anomaly (loud noise) in a second unit.

Result

Permanent Monitoring continues with analysis and discovers temperature warning. Performed a magnetic inspection of gearbox and discovers metal pieces in gear oil, another gearbox defect.

Metal pieces indicate defect of gearbox

Temperature Alert

Business Case: Monitoring



MONITORING SAVES 200 THOUSAND EURO OR 800 MIL REAIS

Without Permanent Monitoring

With Permanent Monitoring

312 thousand euro 112 thousand euro

Crane use

Loss of energy production

/

Downtime: 3 WTG for 60 days3.000.000 kWh

3 1

/

Downtime: 1 WTG for 60 days1.100.000 kWh (1 WTG reduction to 70%)

Total costs

Business Case: Monitoring

200 kEUR

Total savings



Company

Challenges



Summary

AGENDA



TECHNICAL INSPECTIONS MINIMIZE MAINTENANCE EFFORTS AND IMPROVE AVAILABILITY

Advantages of technical inspections

Weather effects can cause massive damage which may impede, or even preclude, operation

Technical inspections help to obtain clarity on the current status of the turbine, identify defects as early as possible, and as a result avoid costly consequential damage

Small disturbances can cause damages of large parts and longer downtime. Often only detected by inspections

Cable on sharp edge

Rotor blades might be needed to exchanged instead of quickly fixing them during inspections.

“Small” undetected issues like cables on sharp edge could cause fire and lead to loss of entire turbine

Consequences if inspections are not made



TECHNICAL INSPECTIONS CAN BE CATEGORIZED IN GENERALIZED OR SPECIALIZED AND CONDUCTED IN EVERY PHASE

Most relevant inspection types and phases

“General” technical inspections

Rotor blade inspections (by rope access technology or by telescope)

Blade angle measurements

Quality control during production process

Assistance in the construction phase

Damage appraisal and damage analysis

Inspections can be realized nearly in every stage



NOT TIMELY CONDUCTED INSPECTION CAUSED REPLACEMENT OF ALL BLADES

Business Case: Technical Inspections

Strong thunderstorms in the region. Planned rotor blade inspection in two wind farms were preponed. Inspections discovered a

burn mark residue at the receptor of 3 WTGs

The manufacturer repaired 2 WTG and planned to repair the third WTG only 3

months later

2 months later another lightning occurred and caused strong damage in one rotor blade

of the remaining WTG

In consequence manufacturer had to replace all 3 rotor blades, since this type is no longer

available in the market and all blades need to be equal

Burn mark residue

Open edge of rotor blade



TECHNICAL INSPECTIONS COULD HAVE SAVED 195 KEUR FOR OWNER AND 483 KEUR FOR MANUFACTURER

Repair without prior Inspection

Fixing duringInspection

203 kEUR 8 kEUR

Crane

Loss of energy production

/2.600.000 kWh

/89.000 kWh

Total costs for the wind farm

Business Case: Technical Inspections

3 new Rotorblades

Service teams

380 kEUR

35 kEUR

75 kEUR 7 kEUR

Total costs for manufacturer

490 kEUR 7 kEUR

195 kEUR

483 kEUR

Total savings



Company

Challenges

Permanent Monitoring


Summary

AGENDA



MONITORING AND INSPECTION SERVICES HELP YOU TO MAXIMIZE YOUR PERFORMANCE AND REDUCE YOUR COSTS

help you to represent your interests

in dealing with manufacturers as

well as service companies

keeps you informed about the state

of your wind park and the work of

your service providers

ensures quick reaction in case of

disturbances

reduce operational costs and

production losses significantly

Making your investment more profitable!

WINDWERK offers ...

Competence in monitoring and operations of

ancient and modern turbines of major

manufacturers (e.g. Suzlon/Senvion,

Enercon/Wobben, Vestas, GE)

Highly qualified, multilingual teams

Specialized network of experts, service

providers, suppliers and manufacturers

Use of proven systems, stable and

independent IT

Application of European best practices

Monitoring and Inspections ...

Rua Correia Dias 184, 11o andarSão Paulo (11) 4081 1976

[email protected]

Thomas KunzmannManaging [email protected]

Fabricio KleinOperations Manager Permanent [email protected]

T H A N K Y O U - W E R E M A I N A T Y O U R D I S P O S A L !

27

Visit us at the German PavilionBooth C131-136!

maximizing performance by windfarm services

Documents