managing resources maximo

Jason Watson

Acciona Energy

Implementing Maximo in the Wind Industry

The wind industry is a rapidly growing industry in Australia and aroundthe world.

The proper management of the wind turbines and associatedinfrastructure is important in maximizing the performance and returnon these assets.

MXES is being implemented globally by Acciona Energy as theprincipal tool for asset management.

Acciona

Acciona Group is a leading corporation in the development, promotion andmanagement of infrastructures and services oriented towards sustainabledevelopment and social welfare

Acciona Group comprises:

• Infrastructure

• Real Estate

• Energy

• Water

• Logistics and Transport

• Urban & Environmental Services

Acciona Energy

Acciona Energy is a global leader in renewable energy

Horizontal integration of activities

B. Major projects in renewables (30.06.2006)

Biomass: 33 MW -30% of the primary biomass in Spain-

Wind: 3,876 MW installed -6% of the world total- (2,636 MW part., 2,008 attr.)

Solar: 18,8 MW PV (35% of the Spanish market) and 19 MW thermal installed

Small hydro: 59 MW –3.6% in Spain-

Biofuels: 35,000 tonnes per year biodiesel plant (1.2 Mtonnes in project)

ACCIONA also has 115 MW in cogeneration

Acciona Energy, Leader in wind

A. Wind power / leadership in several activities

First developer

and constructor

of windparks

in the world

Eighth world

manufacturer

of wind turbines

Fourth world

operator

of windparks

Third largest owner of

wind energy assets in the

world, and second in Spain

Acciona Energy is:


B. Present in the entire wind energy value chain

Wind turbine design

Wind turbine manufacture

Development

Financing

Turnkey

Property Local partners

O&M Local and remotecontrol24h x 365 days

Marketing of energy and CO2

Under development

Selection of sites, environmental impact,relations with local authorities

Construction, admin.processes and project management

Financial analysis,structuring and due diligence

Vertical integration

In-house technology


Attributable Power (MW) Country Total Power (MW)Number of Installations

TOTAL

Spain

Germany

France

USA

Canada

Australia

Italy

Greece

Hungary

2,951

116

94

86

60

66

33

35

24

2,315

116

47

12

20

33

17

35

11

C. Wind power capacity owned by Acciona Energy by country (30.06.07)

101

10

14

2

2

1

3

1

1

3,465 2,606135

Maximo in Acciona Energy

Maximo 6.2 is being implemented by Acciona Energy across its globaloperations.

Project based in Spain and Australia.

Spain – focused on the implementation of maintenance of windturbines

Australia – focused on the commercial and financial aspects

Consolidation of system into a global system

Maximo in Acciona Energy

Drivers for the implementation of Maximo

Technical• Technically complex machines, requiring ongoing preventative,

predictive and corrective maintenance

Commercial• Significant investment, where return is based on the production of

the turbines

Stakeholder• Numerous stakeholders with diverse expectations from the turbines


Challenges within the wind industry

• Rapidly growing industry – averaging 30% per annum

• Rapidly developing technology – 100 x increase in power output in25 years

• Complexity of machines increasing

• Attitude to wind power

Technical – Wind Turbine

Technical chracteristics (I)

• Variable speed

• Rated power: 1,500 kW

• Rated voltage: 12 kV

• Generation frequencies: 50 / 60 Hz.

• Generator: double-fed asynchronous

• Rotor diameters: 70 and 77 m.

• Hub height: 60 and 80 m.

• Three bladed wind turbine oriented windward

• Horizontal shaft

AW-1500 turbine in the Vedadillo windpark (Navarre)

4. AW-1500 wind turbine


Generator

High speed shaft

Gearbox

Doubleframe

Main shaftHub

Essential components

2 BearingsSupport

Independentpitch controlfor eachblade


Asset Management on the Turbines has several key points

A large number of parts replaceable and serial number tracked

Complex structure of parts and components

Differing expected lifetime of major components• Gearbox 10 years• Blades 25 years• Generator 25 years• Tower 50+ years

Use of Maximo to track the life of components

Turbine Performance

Turbines are highly automated

• Detect and respond to wind conditions

• Detect and respond to grid conditions

• Detect and respond to plant condition

Turbine Performance

Turbines are highly efficient

Achieving at least 90% availability

Conversion of 50% wind energy into electricity

Wind farms designed to achieved 30-40% capacity factor – actualoutput versus theoretical maximum output

Accurate forecasting 24-48 hours in advance


Additional infrastructure on a Wind Farm

• High voltage substations

• High voltage cables and overhead lines

• Communication and SCADA system

• Roads, gates, culverts and civil infrastructure

• Meteorological monitoring stations

• Facility buildings

• Vehicles and tools

TechnicalHow does Maximo fit in?

• Provide an accurate record of installed equipment

• Provide an accurate history of turbines and plant

• Schedule predictive and preventative maintenance

• Track corrective maintenance

• Provide information for engineering analysis

• Link to information sources (commissioning records etc)

Installed equipment

Utilise the Location / Asset / Item structure to mirror turbine

• Tracking of serial numbers

• Number and location of components – optimization of spares

inventory

• Specification templates – technical specifications

• Item assembly structures - management of the structure

• Alternate items

Installed equipment

Interaction with the inventory and purchasing system

• Correct identification of parts from structure

• Consolidation of demand to stores and warehouse

• Optimisation of purchasing

Waubra Wind Farm

Site (approximately 173km²) is a series of hills and high plateaus whichform part of the Great Dividing Range, approx 20km from Ballarat

Site consists primarily of cleared agricultural land used for sheep andcattle grazing and potato growing

128 x 1.5 MW wind turbines, with associated access tracks, substationsand an operations centre

A total installed capacity of 192MW

Green energy for 143,000 households – more than enough to powerthe City of Ballarat

Waubra Wind Farm

Maintaining Wind Turbines

Maintenance requirements of Turbines

• 24/7 operation

• Service every 6 months 6 monthly 12 monthly 24 monthly

• Gearbox refurbishment every 10 years

• Average personnel requirement of 1 technician for every 6 turbines

Maintaining Wind Turbines

Work Orders

Incorporates permit requirements for:• High Voltage• Working at heights• Confined space

Panned and Actual Permits – from Job Plans

Commercial Reality

The profitability of a windfarm operation is dependant on:

• Maximising the output from the available wind

• Minimising the cost of operation

Maximising Production

There are two key measures of turbine performance

AvailabilityUtilisation

Availability is the measure of when the turbine is running, or capable ofrunning

Utilisation is the measure of actual power output vs theoretical poweroutput

Both are adversely affected by stoppages due to alarms, defects andscheduled stops for maintenance.

Maximising Production -Minimising stoppages

Alarms

24/7 hour control room for the immediate reaction to alarms60% of alarms can be reset remotely

24/7 on-call techniciansResponse time a key performance indicator

Engineering analysis of alarms to identify root cause• All stoppages raised as work orders in Maximo• Response to alarm recorded and measured• Failure Codes in Maximo utilised to assist in engineering analysis• Global consolidation of turbine data to provide large dataset for engineering

analysis


Defects

Identification of all defects as work orders in Maximo

Priority system to address defect1. Immediate attention2. As soon as practicable, within 2 weeks3. At next scheduled service4. Ongoing observation

Priority system for equipment as well1. Major electrical and communication infrastructure2. Minor electrical and communication infrastructure3. Turbine4. Civil infrastructure


Scheduled stops

Scheduled stoppages are used for preventative and predictivemaintenance

Duration of stoppage minimisedEfficient work practicesEffective inventory controlClear and precise work instructionsMultiple work shifts

Planning based on forecast wind speed to improve utilisation requiresgreater flexibility and accurate knowledge of planned work

Minimising Cost

Once constructed, maintenance is the major ongoing cost in theoperation of the wind farm

Minimistion of cost is achieved through the balancing the maintenancerequirements to appropriate levels of resources

Efficient work practicesOptimisation of inventoryBalancing the resources with the maintenance requirements

Effective use of Maximo improves the management of these areas.

Stakeholders

There are a large number of stakeholders within an operating wind farm

Commercial partners Joint venture partners

Electricity industry Grid connection utilities NEMCO Energy Retailers

Community Landowners Local community Public

Stakeholders - Commercial Partners

Acciona Energy wind farms in Australia are joint ventures.

Complex legal and financial aspectsSeparate chart of accounts for each legal entity

PWED

AEO

AWP Contractors

PWED

AEO

AWP

Contractors

AEO

PWED

AEO

Contractors

Construction Warranty Operation

Stakeholders – Electricity Industry

Wind farms connect into the National Grid

Wind farm must;• Operate stably and securely in National Grid• Meet the power generation obligations to the energy retailers• Coordinate maintenance and operations with other generators and

utilities within the gird

This requires reliable turbine operation and accurate planning

Stakeholders – Community

Wind farms have an impact on the surrounding community.Large public interest in the wind industry.Wind farms must be responsible corporate citizens.

Maximo assists the wind farm in providing

• Accurate information for reporting and communication withinterested parties

• Management of the contractual obligations of the wind farm withland owners

• The ability to record and react to changing local conditions

Stakeholders – Land owners

Management of land owner requirements essential to the construction andoperation of the windfarm.

Record of land title and installed assets

Lease payments for access to land

Management of local conditions Land usage (cropping etc) Correction of defects

Communication with land owners Upcoming work plan Performance of turbines within their property


Lease payments

Land owner lease payments based on: Access for the planning and development of windfarm Lease of land for the installation of meteorological monitoring

stations Access for the construction of the windfarm Lease of land for the installation of turbines and substations


Lease payments

The management of the lease is very important Key dates to meet Payments are linked to CPI Land titles change hands Long term contracts

Waubra has 36 directly effected land owners with93 land titles

Stakeholders – Land ownersLease payments

Customised lease application• Location structure for land titles• Leased assets for land access rights, met masts, turbine

foundations• CPI increase calculated using currency exchange functionality

Stakeholders – Community and PublicCommunity Reference Group as a link between community and the

wind farm

Accurate information and follow up on raised issues

Implementing Maximo in the Wind IndustryGlobal Consolidation

Master Maximo system willreside in Spain

Local systems in Spain, UnitedStates and Australia

Consistent design and structureInformation merged via the MEAapplication into consolidateddatabase

Consolidated MaximoSpain

Spain United States Australia


Summary

The emerging wind industry is dependant on accurate and effectiveasset management.

Maximo provides a range of tools applicable to the management of thedevelopment construction and operation of the wind farm

Cope with the complexity of a wind farm Provides existing tools that can be leveraged to meet the wind

farm requirements Simplify the requirements for the people working within the

rapidly growing industry


Thank you

www.waubrawindfarm.com.auwww.waubrawindfarm.com.au

www.acciona-energia.comwww.acciona-energia.com

managing resources maximo

Documents

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