voith industrial services wind gmbh - · pdf filevoith industrial services wind | 20090408 | 2...

Voith Industrial Services Wind

GmbH

Presentation vindmøller i udland

Fredericia 14.10.10

Voith Industrial Services Wind | 20090408 | 2

Profit from Operations € in million Sales € in million

Dynamic growth and solid profits

over decades

We have stronger growth than many

listed companies

Positive results even in times of

recession


Profit from Operations € in million Sales € in million

Voith Turbo

24%

Voith Hydro

22%

34%

Voith Paper

20%

Voith Industrial Services

Sales

Sales and Employees 2008/2009

by Division

Voith Hydro: € 1,085 million

4,681 employees

Voith Industrial Services: € 1,018 million

19,118 employees

Voith Paper: € 1,743 million

9,500 employees

Voith Turbo: € 1,232 million

5,428 employees


Voith is innovative

Voith – Where smart people like to

work

11,000 active patents

400 new patents every year

Voith Industrial Services Wind | | 5

Our fields of activities

Voith Industrial Services Wind specializes in providing complete process services for

wind power plants: from single wind installations to wind farms.

Onshore customer groups and plant types served:

Private Owners and Operators

Investment companies (Funds)

Independent Power Producers (IPP)

Electric utilities

Wind turbine manufacturers


The business model of Voith

What does Voith accomplish to be the first choice of the customers?

Voith as service provider at OEM stage for large WTG´s till 3 MW

Full line provider incl. general repair + frequency converter

Expertise by experienced employees with OEM´s

Quick response time by remote monitoring of WTG´s (24/7)

Flexible logistics concept: guarantee of availability for spare parts

Cost certainty by long-term frame and service contracts

Decentralized service pojnts (close-by wind farms)

Beirat VIWS |Hamburg 2010-08-06 | 7

Know-how for complex technology: our WTG portfolio

Voith supplies service for over 600 MW of 7 different OEM:

Nordex/ Südwind

Vestas/ NEG Micon

Gamesa Eolica

Siemens Windpower

GE/ Enron/ Tacke

DeWind

E.n.o. Energy

VIWS - Übersicht Bestandsanlagen

(Stand: 31.07.2010)

Siemens

4%

(4%)

Nordex

35%

(42%)

DeWind

24%

(20%)

GE / Tacke

9%

(16%)

Vestas / NEG

Micon

25%

(18%)

Gamesa

3%

(0%)


WTG portfolio of more than 30 different types:

DeWind D4

DeWind D6

(1 MW)

DeWind D6

(1,25 MW)

Vestas / Gamesa DeWind GE Wind Siemens Nordex

Tacke TW 600

Tacke TW 600e

NM 64c

NM 72c

NM 82

Nordex N 60/62

Südwind S 70/77

(incl. MD 70/77)

V 80/ V82

(incl. Gamesa G80)

AN Bonus 1,3 MW

GE 1,5 Series

(incl. Tacke &

ENRON)

AN Bonus 450 KW

AN Bonus 600 KW

AN Bonus 1 MW

AN Bonus 2,3 MW

M 1500/1800

NM 48 / NM 52

NM 60

V 39/ V 47/ V 52

Nordex N 80/ 90

2.500 kW

Nordex N 27/29

Nordex N 43

Nordex N 50

Nordex N 52/54 till

1 M

W

till

1,5

MW

ti

ll 2

,5 M

W

DeWind D8

DeWind D8.2

(2 MW)

GE 2.X Series


Quality What is going wrong in maintenance of windturbines ?

old maintenance manuals

old or no work instructions

no certified processes (ISO 9001/14001/OHSAS 18001)

unscheduled repairs reduce technical availability

unqualified personnel

insufficient (regular) training

non availability of spare parts

response times and response quality in monitoring

unproper documentation of executed works

escalation processes do not exist

Insuffcient insurance & claim management

Result: Insufficient Technical Availability, poor performance

Monteurstreffen VIWS 2010| 10

Quality What is Quality Management ?

Up-to-date maintenance manuals

Proper work instructions

Certified processes (ISO 9001/14001/OHSAS 18001)

(Preventive) turbine audits

Team audits

Regular training

Regional dedication of teams

Training of monitoring staff for „intensive care“ of turbines

Electronical documentation

Efficient escalation processes

Efficient Insurance & Claim Management


Quality management Product management: Escalation processes

Vestas/NEG Micon

Roman Müller

Mario Zengerling

(Team Thüringen I)

Siemens/AN Bonus

Thomas Kühnrich

Jan Linke

(Team Lübeck II)

MD70/77 Baureihe

Mario Bemerl

Peter Schüler

(Team Düren)

Nordex

Thomas Kellermann

Sven Gerke

(Team Karstädt)

DeWind

Andreas Bauer

Marko Nitschke

(Team Bremen)

Gamesa

Roman Müller

Avelion Fernández

(Team

Ludwigshafen)

GE / Enron / Tacke

Jens Monsees

Martin Lewinske

(Team Heide)

1st Level Support

„Product manager/

Technician“

Team reports

Problem

2nd Level Support

„Productmanager

Project leader“

3rd Level Support

Engineering


Background:

Knowledge of variations of different OEM

escalation processes

Goal:

clear responsibilities

bundling of technology - Know-how by accumulation of technician‘s and backoffice

know-how

Transparency for all participants in process

Product management: Why?

Konsequenz: je Technologie ein verantwortliches Team

aus Projektleiter und Monteur


Quality management Modular training concept


Region-wide service network in Germany

continuous development of the

service points in Germany

Number of service points: 15

Number of service teams: 30


Maintenance Management The Voith Remote Monitoring Concept

24/7 reactive remote monitoring

24/7 active remote monitoring

Servicehotline

Management of the service intervention

3-shift-system


acquisition of customer personal data

acquisition of the supervised wind farms

acquisition of the failures

Maintenance Management WIS - Database

daily planning of the serviceteams

three times a day: verification of the WTG´s


Flexible logistics concept: guarantee of availability for critical spare parts


Based on availability maintenance planning by using the IMS-system with life

cycle datas of all WTG´s & components

condition monitoring

defined escalation process in order to reduce downtimes to minimum

wind farm specific profitability analysis

system dependent optimizations

quality audits

The focus is on the optimization of the technology

Future orientated maintenance and engineering concept


Erection, modernization & optimization of WTG´s

Exchange of big components: for example:

- gearboxes, rotor blades, generators, drive train / transmissions, hub, nacelle

Repowering of WTG`s

The key task consists of the coordination of resources (for example: cranes,

transportations, service technicians).

Project Management of complex projects

| | 20

Voith Service Plus New innovative Service Concepts

| | 21

For windfarms >25 MW

highly homogenous turbines

Safety due to longterm contracts

with calculated risk and chance

Efficient cost control due to „flatrate“

Optimization of personnel useage

Focussed training on fleet

fast response and defined processes

Optimization of spare part management

Reporting for adequate cost control

lean overhead structure

Availability guarantee

Innovative Service contracts: Voith Service Plus


„The Voith Service Plus can increase the income from existing parks“

Step 1:

Audit

Technical and economical total

check

Step 2:

New O&M Concept

Preventive Maintenance and Finance

planning. O&M optimized according to

down times and income.

Optimized Contracts.


Reference Site: with the Voith Service Plus the availability was increased by 5 % and the earnings by 6% ….

Zeitraum: Sept. 03 - Aug. 04 / Sept. 04 - Aug. 05 / Sept. 05 - Aug. 06

94,34%

96,73%

97,60%

90%

91%

92%

93%

94%

95%

96%

97%

98%

99%

100%

Sept. 03 - Aug. 04 Sept. 04 - Aug. 05 Sept. 05 - Aug. 06


Zeitraum: Sept. 03 - Aug. 04 / Sept. 04 - Aug. 05 / Sept. 05 - Aug 06

0 kWh

2.000.000 kWh

4.000.000 kWh

6.000.000 kWh

8.000.000 kWh

10.000.000 kWh

12.000.000 kWh

Ertrag 01.09.03 -

31.08.04

Ertrag 01.09.04 -

31.08.05

Ertrag 01.09.05 -

31.08.06

….i.e.: increase from power generation around 5 % reducing the non-producing periods by approx. 34 %...

Ausfälle in kWh


… with slight increment of the Service Costs taking into account the lack of repairs in the previous years

Zeitraum: Jan. 04 - Aug. 04 / Sep. 04 - Aug. 06

0 €

1.000 €

2.000 €

3.000 €

4.000 €

5.000 €

6.000 €

7.000 €

8.000 €

Servicekosten Wartungspauschale Gesamtsumme


… with slight increment of the Service Costs taking into account the lack of repairs in the previous years (incl. price increase of former OEM service provider

Zeitraum: Jan. 04 - Aug. 04 / Sep. 04 - Aug. 06

0 €

1.000 €

2.000 €

3.000 €

4.000 €

5.000 €

6.000 €

7.000 €

8.000 €

Servicekosten Wartungspauschale Gesamtsumme


… resulting in an better income by approx. 6%.

Zeitraum: Sept. 03 - Aug. 04 / Sept. 04 - Aug. 06

-20.000 €

-10.000 €

- €

10.000 €

20.000 €

30.000 €

40.000 €

50.000 €

60.000 €

70.000 €

80.000 €

Ertrag pro Monat Kosten pro Monat Bilanz


Co-operational activity concept and failure management

increase of site presence coordinating the planned visits for maintenance by the

Service Team and Inspections by the operator´s manager

quickest site presence at failures by the Operators and /or the Service

Common data levels and Interfaces

Development from aimed Reengineering Concepts supported by huge amounts of

Data.

Utilization of operational data allowing the Service to apply preventive Maintenance.

Partnership with separate Responsibility

Controlling function from Operator and Service with common objectives: best income

for the customer.

The ProfitGuard - a product resulting from a Partnership between Operator and Service Provider


References Wind – Conergy Services Product cooperation: „Conergy Profit Guard“

professional judgement of WTG´s

down times reduction by analysis and action plans

preventive maintenance, which makes sure that the

profitability of the WTG´s increased

increase of availability of WTG´s

in comparison with the conventional operating

management & maintenance till 6% economies scale

with the Conergy ProfitGuard


References Wind – e.n.o. energy Grow jointly – erection & service of the WTG type „e.n.o. 82“

frame contract for the erection of the WTG type e.n.o.

82 in Germany (across Europe in negotiations)

frame contract for long-term maintenance of e.n.o. 82

in Germany (across Europe in negotiations)

troubleshooting service / remote monitoring (24/7)

object spare parts

converter services

general repairs


References Wind – International Power frame contract for operation of different WTG types

a subsidiary company of International Power Plant

(international power generator; is considered to one

of the worldwide leading, independent power

generator)

Supervise volume for Levanto:

83 WTG (NM82 / V47 / GE1.5 / Bonus1300 / N60)

with an overall performance of 99 MW


References Wind - Gamesa Eolica, Gamesa Wind Erection of wind energy turbines

Erection, as well as the completion for

commissioning of WTG´s of the type G52/G58 at

different locations in Germany

Commissioning of WTG´s of the type G80 in

Poland

documentation of the erection activities


References Wind - Plambeck Erneuerbare Energien Optimization of different WTG types

planning of all on-site services, which are relevant

for the availability

disassembling & reaasembling of big components

coordination of the subcontractors:

- in the fields of cranes, transportations,

maintenance

pro-availability spare part management

reporting system for the insurer

improvement / optimization of critical prefabricated

parts (for example: slip ring motor)

Key-Account-Management:

regular information exchange with the operator &

the plant manager


References Wind - EnerVest AG Wind farm redevelopment

wind farm (WF) redevelopment of the WF Staffelstein

8 x Südwind S70 (12 MW)

Installation of a wind farm network

Retrofit der Umrichter und Kupplungen

redevelopment of all pitch- & azimuthsystems, brakes

service for generators (incl. overhauling of the slip

ring motors) und gear boxes

upon completion long-term service & maintenance

contract

supervised volume for Enervest:

25 WTG (S70 / GE1.5 / NEG MICON NM60) with an

overall performance of 31 MW


References Wind – e.disnatur Erneuerbare Energien Pilot project: Vestas

3 wind farms with 14 wind turbines of the type V80 and

V90

overall performance: 28 MW

location: Germany (Mecklenburg – Vorpommern and

Brandenburg)


References Wind – FKI Engineering Ltd. First project abroad: Austria

11 wind turbines of the type D8 and 19 wind turbines of

the type D6 with an overall performance of 45,75 MW

First „Voith Service Plus“ – contract

this contract includes particularly:

- maintenance

- servicing flat rate

- availability warranty

- bonus-malus-agreement

- spare part flat rate and the availability warranty

of them

term of contract: 8 years


Your expectations

What does the customer expect from an independent service provider?

Full service from one source for WTG´s of all OEM´s

Economic safety of a strong partner

Experience & expertise

High technical availability by flexible spare part management and 24/7- remote

monitoring

Early detection of damage by latest WTG diagnostic

Maintenance / service contracts with long-term cost certainty

Transparency


Monteurstreffen 2010 Produktmanagement: Aufgaben & Verantwortlichkeiten

technischer Support Monteure, DFÜ-Mitarbeiter und Projektleiter

herstellerbezogene Dokumentation

- Bereitstellung für alle VIWS Mitarbeiter

herstellerbezogene Upgrades und Optimierungen

- Mitwirkung aller VIWS Mitarbeiter

- Erläuterung der Vorteile und Wirkungen

herstellerbezogenen Arbeitsanweisungen und Wartungshandbüchern (bei Bedarf)

herstellerbezogene Schulungen und Unterweisungen von Monteuren, DFÜ-

Mitarbeitern und Projektleiter

- Vorbereitung von Hilfen zur Fehlersuche und Eingrenzung von sporadischen Fehlern

- Erläuterung spezifischer Probleme oder Zusammenhänge


Attribution of the Product Managers to the OEM

Vestas/NEG Micon

Roman Müller

Mario Zengerling

(Team Thüringen I)

Siemens/AN Bonus

Thomas Kühnrich

Jan Linke

(Team Lübeck II)

MD70/77 Baureihe

Mario Bemerl

Peter Schüler

(Team Düren)

Nordex

Thomas Kellermann

Sven Gerke

(Team Karstädt)

DeWind

Andreas Bauer

Marko Nitschke

(Team Bremen)

Gamesa

Roman Müller

Avelion Fernández

(Team

Ludwigshafen)

GE / Enron / Tacke

Jens Monsees

Martin Lewinske

(Team Heide)


In case of problems in the field, the following level of escalations are effective:

1st Level Support First contact person in case of occured

problems is the remote monitoring or

the responsible project manager for the

wind farm if the problem can not solve in the 1st

level: forwarding the problem to the 2nd

level

if the problem can not solve in the 2nd

level: forwarding the problem to the 3rd

level

team give notice of a problem

2nd Level Support

3rd Level Support

contact person, if the problem can not

solve in the 1st level are the product

manager

contact person, if the problem can not

solve in the 2nd Level is the technical

department

voith industrial services wind gmbh - · pdf filevoith industrial services wind | 20090408 | 2...

Documents