World Class Windturbine Maintenance Project

Transcription

1 World Class Windturbine Maintenance Project Ir. Johan Prinsloo, Technical Director A presentation by IMS International Your partner in Integrated Maintenance & Asset Management Solutions Copyright 2014 by IMS International B.V. This presentation, nor any part of it, may be copied, circulated, quoted, without prior written approval from IMS International B.V. 2014

2 Introduction Participants of WCWM project ASSET & MAINTENANCE MANAGEMENT SOLUTIONS From strategy up till operational excellence Responding to Dutch World Class Maintenance ambition Taking the engineering & consulting services of KEC and Filanet one step further Copyright IMS International 2

3 HIGHER EDUCATION University of Pretoria BEng Electronic Engineering BEng (Hons) Electronic Engineering AIR FORCE SECURITY OFFICER South African Defence Force (Compulsory Military Duty) CO-FOUNDED ANSYS TECHNICAL DIRECTOR/BUSINESS DEVELOPMENT PRETORIA ANSYS LISTED ON THE JHB STOCK EXCHANGE 2011 FILANET Maintenance and Systems Engineering RCM / RAMSHEC Digitized Maintenance Management Systems Wind Farm O&M design Business Development consulting proposals/negotiation Aerospace designs Financial modeling.. DEFENCE Naval, Army, Air Force projects: Advanced Weapon Integration, Avionics, GBADS, Submarine consoles, Logs Equipment SPACE Satellite interface design, Launch vehicle interface design MINING Rope testing, Maintenance Management solutions RAIL Integrated Train Condition Monitoring Systems, Vehicle Identification systems/tracking, Locomotive Computer systems INDUSTRIAL Maintenance Management Systems, Condition Based Monitor Systems 1

4 Digitized Maintenance Goals Control room Maintenance management & monitoring Field support Knowledge management Consistent data collection Asset based procedures Logistics, resources, spares & tools optimization Track & trace Maintenance management dashboard handheld

5 FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS) MMS WEB PORTAL Reporting Planning Controlling Scheduling Metrics MMS SERVER HUMS (Health and Usage Monitoring System) will be installed in the Asset Environment. HUMS will interface with the MMS Server via the HUB, and link into all available Sensors to provide a real-time predictive monitoring capability. HUMS also links with PDA to allow realtime tracking (location) within the HUMS sensor range. Uses Cellular Network (3G, GPRS), Telephone Modem if cellular network is not available, or satellite communication ASSET OWNER HUB PDA HUMS Radio Frequency ASSET OWNER SERVER RFID Tag Wireless, Radio Frequency, etc. SENSORS Automatic Measuring Points Automatic Sensors Condition Monitoring Points Asset Owner uses MMS as Single Integrated Predictive Maintenance Management Solution Optimize maintenance based on consistent, reliable data. Incident and problem management Act Monitoring of maintenance and operations Schedule maintenance tasks MMS Plan Maintenance tasks, information on logistics, spare parts and tools Check Feed back of maintenance data, completed tasks, inspection data, pictures, parameters, data of remote sensors Routing, maintenance procedures, safety, environmental instructions Do Just in time, relevant technical, routing and logistics information Remote support

6 FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS) Digitized into 345 consistent tasks and 3 scheduling levels DELTA WT MAINTENANCE AND INSPECTION SCHEDULES Knowledge management FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS) WEB PORTAL Filanet supplied Handheld Knowledge management Delta / Oliveira Control Room / Management Dashboard Delta OLAZ II Live Pilot Tests performed in Q & Q3/Q by Delta technicians Owner Inspection for Kreekrak Q1 2014

7 FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS) WT (OLAZ II Vestas V47) Maintenance / Inspection Schedules fully digitized and available through the webbased MMS portal (345 tasks, 3 scheduling levels). WT (Kreekrak) owner inspection fully digitized and available (449 tasks, 3 scheduling levels) Live testing performed by Delta technicians in Q4 2012, Q3/Q and Q using the Filanet supplied handheld and tasks loaded via the MMS portal. Use of handheld / web solution for maintenance / inspection confirmed, however, several lessons learned in the process. Excel based reporting functionality Interface to management dashboard and Delta OPS data developed

8 FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS) MMS Web Portal Screenshot 1 (shows status of high level scheduled tasks) Completed Tasks, shows status (Green = no issues, Red = Issues to be resolved) See next slide for detail of Task ID Excel Generated Reports

9 FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS) MMS Web Portal Screenshot 2 (shows status of Task ID 10543) Specific task not completed successfully, requires further action from Delta technicians

10 FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS) MMS Web Portal Screenshot 3 (Shows details of Excel Generated Report for Task ID 10543) Detail fields of the Excel report will form the basis of the data inputs from the Filanet MMS solution to the Delta Oliveira Control Tower / Management Dashboard. From the data a consistent database will be populated that will show completed maintenance / inspections and open issues. This will also allow for engineering analysis to be performed on the open issues (spare parts analysis, root cause analysis, revised maintenance / inspection profiles, etc.), and for automatic generated reports to be issued to internal staff and / or external repair / parts suppliers to address the open issues. Pictures

11 FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS) LESSONS LEARNED: Filanet MMS software was developed in sequential format (one task scheduled after the other and requires a task to be completed prior to moving to the other, flexibility provided in the way the tasks are scheduled, therefore the 3 levels of scheduling [all tasks at once; section per section; sections within each section). Based on the maintenance / inspections routes used by the technicians through the live pilot it became clear that the software needs to be more flexible to allow technicians to complete individual tasks without having to be forced in a sequential manner. Filanet MMS system was initially set on active communications with the web portal (as tasks are completed they are transferred in real time to the server for display, and scheduled tasks are downloaded in real time when the user logs onto the handheld). Due to the wind turbine metal structure real-time communications are not available at all times and this upsets the workings of the solution in terms of data uploads and downloads. The issue was resolved for the pilot whereby manual uploads and downloads are performed, however, for long term solutions the issues of real-time, or near-real time communications, requires further investigation and implementations.

12 FILANET RELIABILITY CENTERED MAINTENANCE (RCM) SLIDE 1/3 Phase 1 System Identification and Function Definition for Vestas V47 (OLAZ II). Phase 2 Failure Mode and Effect Criticality Analysis (FMECA) based on data from phase 1. Phase 3 Identification of high risk items and using the decision logic tree with feedback into the current maintenance concept to assess improvements.

13 FILANET RELIABILITY CENTERED MAINTENANCE (RCM) SLIDE 2/3 Agreed RCM Process for Delta V47 OLAZ II

14 FILANET RELIABILITY CENTERED MAINTENANCE (RCM) SLIDE 3/3 LESSONS LEARNED: The Vestas V47 (OLAZ II) is a highly reliable turbine. The application of the RCM process is limited in its ability to influence the current maintenance profile. The prime benefit of the RCM during the pilot is allowing the technicians and management to think of the turbine in terms of its functions, and the effect of loosing the functions, rather on pure failure of components and systems. This assists in finding the root causes of problems and cost effectively addressing them rather than spending large amounts of replacing components and parts. The RCM process is also a good learning and personal development process for the Delta staff and allow them to seamlessly apply the process to turbines that exhibits constant problems and failures.

15 Welcome J. Prinsloo Asset Management Specialist Edition V1.0 IMMS Android App Asset Management Specialist Edition Welcome J. Prinsloo V1.0 Welcome J. Prinsloo IMMS Maintenance Manager Further development towards asset & maintenance management solutions by IMS International More information during the afternoon session ASSET & MAINTENANCE MANAGEMENT SOLUTIONS 15