maximizing performance by windfarm services
TRANSCRIPT
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
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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
1st of September 2016
Company
Challenges
Permanent Monitoring and IT
Technical Inspections
Summary
AGENDA
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
1st of September 2016
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
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
1st of September 2016
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
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
1st of September 2016
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
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
1st of September 2016
Company
Challenges
Permanent Monitoring and IT
Technical Inspections
Summary
AGENDA
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
1st of September 2016
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
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
1st of September 2016
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
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
1st of September 2016
Company
Challenges
Permanent Monitoring and IT
Technical Inspections
Summary
AGENDA
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
1st of September 2016
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
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
1st of September 2016
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
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
1st of September 2016
In partnership with:
OUR SOLUTION FOR INTEGRATED AND PERMANENT MONITORING OF DIFFERENT BRANDS: WIS
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
1st of September 2016
• 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:
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
1st of September 2016
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
In partnership with:
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
1st of September 2016
OLD FASHIONED AND MODERN COMMUNICATIONS CHANNELS CAN BE USED TO ACCESS DATA
In partnership with:
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
1st of September 2016
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
In partnership with:
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
1st of September 2016
• 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
In partnership with:
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
1st of September 2016
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
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
1st of September 2016
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
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
1st of September 2016
Company
Challenges
Permanent Monitoring and IT
Technical Inspections
Summary
AGENDA
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
1st of September 2016
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
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
1st of September 2016
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
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
1st of September 2016
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
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
1st of September 2016
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
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
1st of September 2016
Company
Challenges
Permanent Monitoring
Technical Inspections
Summary
AGENDA
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
1st of September 2016
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
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 !
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Visit us at the German PavilionBooth C131-136!