Effective Operation and Maintenance of Wind Turbines Through Use of Advanced Services Technologies

1
Effective Operation and Maintenance of Wind
Turbines Through Use of Advanced Services
Technologies
GE Energy
Philippe KavafyanGE Energy February
2006Athens, Greece
2
3-5 Wind Project IRR is allocated to risks
associated with variances in energy production
and cost of OM
Cost Variance
Unplanned 70

Service Access
OM
WTG,

Crane Cost
BOP Other

Material Cost

Labor Cost
Planned 30


A Comprehensive OM Strategy is Critical to
Successful Project Economics

3
OM Cost Variability Driven By Product Reliability

• Life-cycle Reliability Has Large Impact on OM
  Costs
• Planned OM can vary from 10 to 35 of total
  cost
• Offshore Access jack up barge, weather, etc.
  add additional cost and variance

Offshore Access
Unplanned OM
Planned OM
Total OM Cost
1
4X
10X
Wind Turbine Reliability
Unplanned OM Cost Significantly Impacted by
Component Reliability
4
Production Impact from Unplanned Events
Event 2
Event 3
Event 1
Access
Threshold
Unplanned
Downtime
Wind Turbine Availability
100
95
90
85
Availability ()
80
75
70
1
2
3
Event
Accessibility Key to Managing Impact of
Unplanned Events
5
Reduce risks to revenue costs from turbine
failures
Loss Revenue due to Increased Wear Tear and
Failure Rates, which results into
reduced Availability
Revenue
Revenue
Customer View
Profit

Additional Costs after Warranty Expires
OM Costs
Customer View
Customer View
0
0
2
20
Year
Year
Current
6
How is GE addressingthis challenge?
7
Apply Services Best Practices

• GE Services
• gt 30,000 Major Equipment Under Service Worldwide
• gt 100 Services-related patents
• Creating New Services Technologies For 20 Years

• Contract Performance
• Parts Life Management
• Asset Management

SmartServices
Increasing Customer Value

• Performance Availability Guarantees
• Equipment Upgrades
• Plant Energy Management

PerformanceOptimizationServices

• Equipment Support
• Anomaly Detection
• Condition Assessment
• Diagnostics Troubleshooting
• Repairs Upgrades

Equipment Services Products
6s
IndustrialEquipment
Power Plant
Medical Equipment
Aircraft Engines
Locomotives
8
Service Technologies for Effective OM
Customer Benefits
Revenue ? COE ? Reliability ? Availability
? Production ?
Multi Pronged Service Approach Required
9
Product Reliability (Prevention)
Serviceability
Goal Design turbines to deliver very
high availability . Breaks Down Rarely

• Approach
• Utilize Design for Reliability Serviceability
• Extended FMEA analysis to define causal events
  and impacts of failures
• Physics-based Reliability Models to understand
  true design and operational limits
• Redundancy of selected components to reduce
  availability impact of failures
• Advanced Controls for Load Management
  Performance enhancement

10
Product / Customer Support
Goal Increase Availability.Minimize Field
Costs. Increase Customer Value
11
Reliability-Based Preventive Maintenance Strategy

Goal Reduce Unplanned Maintenance Increase
Production

• Approach Efficient Risk Allocation
• Contractual Services/Warranty Mgmt
• Predictive Condition Based Maintenance
• Shift Planned Maintenance to Low Wind Period
• Use Reliability Models to Drive Maintenance
  Intervals for Optimal Performance
• Use Site-specific Maintenance Factors to Assess
  Damage Accumulation

12
Condition Based Maintenance
Goal Increase Damage Predictability
13
Offshore Field Services
Goal Effective Access System Logistics for
rapid field response

• Offshore Access Systems
• Commissioning
• Regular OM duties
• Overhaul tasks
• Access/Weather Modeling
• Jack-up Barge Logistics
• Service Friendly Equipment
• Asset Management

Project
Wave Height gt 2.0 Meters
Project 1
48
Project 2
3.5
Project 3
8.1
14
Product Continuous Improvement
Goal Increase Reliability Production
Capability Through Modifications and Upgrades

• Approach
• Identify Opportunities
• Fleet Reliability and Availability Metrics

• Fleet Faults Root Cause Analysis
• Residual Life Prediction Tools
• Introduce Modifications and Upgrades from RCA
  New Technology Development

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Why Services Agreement with OEM?

• More efficient risk allocation between the Owner
  and OEM (Original Equipment Manufacturer)
• Owner Keeps Commercial Risk (Wind Risk, Energy
  Pricing)
• OEM takes on Equipment Performance Related
  Risks
• OEM is in the best position to manage this risk
  in a cost effective manner
• Design and Manufacturing expertise
• Built-in incentives to maximize return on
  investment for the owner a partnership
  arrangement
• Benefits from new products technology
  development

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Summary

• Effective OM is Critical for Reducing Project
  Risks
• Unplanned Maintenance Drives Variationin Cost
  Loss in Production
• GE focused on developing ServicesTechnology
  key to cost effectivelymanaging OM

17
"Effective Operation and Maintenance of Wind
TurbinesThrough Use of Advanced Services
Technologies"
GE Energy
Philippe KavafyanGE Energy February
2006Athens, Greece