2011 Wind Turbine Condition Monitoring Workshop September Broomfield, Colorado

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1 Agenda Safety Topic 2011 Wind Turbine Condition Monitoring Workshop September Broomfield, Colorado Item 1 Item 2 Item 2 Review Action Items Applying Learnings from Condition Monitoring Programs in the Mining Sector to Wind Turbines Bob Williams, Dingo Chief Business Officer Lubricated Asset Experts hard work caring results

2 Agenda Safety Share Mining and Renewable Energy Operational Challenges in Mining The Role of Condition Monitoring in Mining Dingo s Role in Condition Monitoring in Mining Operations Applying Learnings from Mining to Wind Turbines 2

3 Danger of Fatigue While Driving This accident occurred north of Deer Lodge, MT on I-90 in September The driver was a 21-year old male heading east to college. He left central Washington early that morning and fell asleep at the wheel. Drifting off the shoulder of the road and connecting with the end of the guardrail, which only slowed the momentum of the vehicle. The guardrail came through the right headlight, engine compartment, firewall, glove box, passenger seat, rear seat and exited out the driver s side rear window. That is 120 feet of guard rail that threaded itself through the GM Suburban. Fortunately no injuries occurred, but the driver was cited for careless driving. 3

4 Mining and Renewable Energy Eveleth, MN Wind Turbine Wind Farm Iron Ore Mine Coal Fired Electrical Generator 1. Thermal Coal from Kentucky is sent to Minnesota electrical utility 2. MN utility generates electricity to power the iron ore mine & mill 3. Iron Ore from MN is shipped to China and converted to steel 4. Metallurgical Coal from Canada is mined & shipped to China to make steel 5. Steel products from China are shipped to Colorado 6. Steel towers are manufactured in sections for wind turbine supports in Colorado 7. Steel wind turbine housings are manufactured in Colorado 8. Entire structure is shipped from Colorado to Minnesota 9. Homes that house employees of the iron ore mine, coal-fired utility, and wind farm are powered by the wind farm 10. Employees drive to the mines, utility, and wind farms in automobiles powered by gasoline, which was produced in the Canadian oil sands and transported to distribution points in MN 4

accelerating shortage of skilled mining workers. http://www.miningaustralia.com.

5 Operational Challenges in Mining Global demand for mining products is at record levels This leads to a necessity for improved availability of assets Thermal coal producers are under cost and environmental pressures There is a global & accelerating shortage of skilled mining workers. These challenges lead to an urgent need for Predictive & Condition Monitoring tools to be put in place.

6 Role of Condition Monitoring in Mining Condition Based Asset Management in Mining Condition Based Asset Management Condition Based Oil Changes Condition Management Breakdown Avoidance Condition Based Component Changes Monitor lube and component indicators Evaluate condition Evaluate condition Run at optimum drain interval Evaluate optimum drain interval Replace when not economic or possible to correct condition Correct condition when abnormal Determine if component needs to be replaced or pushed Assess other financial & supply factors Modify equipment if required Minimize Lube Cost Avoid Breakdowns Maximize Life 6

7 Dingo s Role in Condition Monitoring Reactive Workflow It Broke! Reactive Workflow Fix It!

8 Dingo s Role in Condition Monitoring Planned Workflow Pre-PM Work ID PM Task Inspection Safety issues Damage Repair Time/Hours-based service Performance Issues Planned Workflow Plan Schedule Execute Done/Not Done, Down Time, Man-hours, Parts, Reason

9 Dingo s Role in Condition Monitoring Predictive Maintenance (PdM) Workflow Pre-PM Work ID PM Task Inspection Safety issues Damage Repair Time/Hours-based service Performance Issues Interpretation & Follow Through to Resolution Repair PdM Workflow Plan Schedule Diagnose Execute Done/Not Done, Down Time, Man-hours, Parts, Reason PdM Data Oil Analysis Vibration Thermography ECM Inspection Done/Not Done, What Found (mag plugs, filters, diagnostics, seals, air systems, etc.), What is Done Continuous Loop to Root Cause

10 Dingo s Role in Condition Monitoring Predictive Maintenance (PdM) Workflow Pre-PM Work ID PM Task Inspection Safety issues Damage Repair Time/Hours-based service Performance Issues Interpretation & Follow Through to Resolution Repair PdM Workflow Plan Schedule Diagnose Execute Done/Not Done, Down Time, Man-hours, Parts, Reason PdM Data Oil Analysis Vibration Thermography ECM Inspection Find It Consistent sampling & analysis Interpret results & determine appropriate actions for abnormal conditions Fix It Process to correct abnormal condition Return to normal as soon as possible Ability to track actions & condition concurrently Done/Not Done, What Found (mag plugs, filters, diagnostics, seals, air systems, etc.), What is Done Continuous Loop to Root Cause The PdM Process Prove It Track meaningful KPIs that illustrate effectiveness Communicate It Communicate results to employee groups

11 Dingo s Role in Condition Monitoring Customer Benefits & Results Some Mining Customers Anglo American Barrick BHP/BMA Freeport McMoRan Kinross Newmont Peabody Rio Tinto Syncrude Teck Non-Mining Customers Vestas ConocoPhillips EuroStar Eastern Municipal Water District Scientifics

12 Dingo s Role in Condition Monitoring Customer Benefits & Results Some Mining Customers Anglo American Barrick BHP/BMA Freeport McMoRan Kinross Newmont Peabody Rio Tinto Syncrude Teck Non-Mining Customers Vestas ConocoPhillips EuroStar Eastern Municipal Water District Scientifics Mining Clients Cost Avoidance Breakeven in Months Payback Ratio Measurable Financial Benefits Client 1 Client 2 Client 3 Client 4 Client 5 Client 6 Client 7 $20.8M $6.0M $27.6M $1.7M $3.8M $7.3M $2.2M :1 3.6:1 4.9:1 3.2:1 2.5:1 5.6:1 5.5:1 *Cost avoidance USD as reported by each client

13 Dingo s Role in Condition Monitoring Customer Benefits & Results Some Mining Customers Anglo American Barrick BHP/BMA Freeport McMoRan Kinross Newmont Peabody Rio Tinto Syncrude Teck Non-Mining Customers Vestas ConocoPhillips EuroStar Eastern Municipal Water District Scientifics Mining Clients Cost Avoidance Breakeven in Months Payback Ratio Measurable Financial Benefits Client 1 Client 2 Client 3 Client 4 Client 5 Client 6 Client 7 $20.8M $6.0M $27.6M $1.7M $3.8M $7.3M $2.2M :1 3.6:1 4.9:1 3.2:1 2.5:1 5.6:1 5.5:1 *Cost avoidance USD as reported by each client Maintenance Benefits Better Utilization of Labor Resources Fewer Catastrophic Failures Lower Repair Costs Lower Maintenance Costs Planning Benefits Raise the Planned vs. Unplanned Maintenance Activity Ratio Support Long Range Planning Efforts Production Benefits Increased Machine Availability Increased Production

14 Applying Learnings to Wind Turbines Working with Vestas-American Wind Technology, Dingo has leveraged more than 19 years of experience, working with mining customers to customize a lubricated component condition monitoring program for the wind turbine market. Breakdown Avoidance & KPI s Condition Based Component Changes Sample Management Condition Intelligence Action Tracking Vestas American Wind Technology Uses the Dingo Trakka Condition Monitoring software database tool Monitors the condition of gearboxes and hydraulic systems throughout North America Monitors all wind turbines that are under service contract by Vestas. Trakka, with an automated alert system, consolidates oil analysis information from multiple laboratories Information is available to Vestas engineers and regional service groups in one centralized database. Trakka Core Modules

15 About Dingo Founded in 1991, Dingo ( is a global leader in offering solutions to heavy asset-intensive operations that affect production, significantly reduce maintenance costs, avoid catastrophic in-service failures and keep assets available. Dingo s Condition Based Asset Management system, now a recognized standard in the mining & energy markets, assures companies a rapid payback with a minimum 3:1 return on investment in less than 12 months. Dingo has offices in Australia, the U.S. and Canada. Trakka and Condition Intelligence are trademarks of Dingo. Bob Williams Chief Business Officer bwilliams@dingo.com

Enhancing Business Performance using Integrated Visibility and Big Data

Enhancing Business Performance using Integrated Visibility and Big Data Manish Sharma Marketing Leader GE Energy Management Manish.Sharma1@ge.com Photograph of Speaker ARC Advisory Group GE Energy Management