EDPR North America Condition Monitoring System Retrofits An Operator s Experience

Transcription

1 EDPR North America Condition Monitoring System Retrofits An Operator s Experience Adam Johs 18 th February 2015

2 EDPR NA Current Active CMS Implementation Vibration Hardware EDPR s installed base of turbines with vibration CMS is growing rapidly Factory installation for new turbines has become an industry standard practice EDPR is also pursuing retrofits of vibration where the business case can be made, typically due to a higher risk profile EDPR recently completed a retrofit of vibration hardware on MW s 2

3 Experiences from the Retrofit Process RFP Released RFP to 6 bidders 3/2014 4/2014 Ran trials to identify preferred vendors and reviewed performance of factory installed systems Did not have strong requirement list/spec due to generally limited experiences Contract Award Installation Technically reviewed bids with NA/EU teams, awarded contract to BK Vibro, negotiated agreements 4/2014 9/2014 Performed technical review with all requirements considered (communication and data access key); was difficult to obtain reviews from all stakeholders, especially non-technical, and to gain final approval for investment Considered monitoring requirements after install, and after included monitoring period, with required manpower Utilized turn-key installation management offered by BKV with preferred vendor, complicating negotiations Performed site surveys, installed 201 units, field commissioned 9/ /2014 Performed site surveys to prepare for installs; completed a model installation to address any issues before full installations begin, and to ensure consistency and quality with install techs Aimed for the later part of the low wind season for installations so that the systems could begin operation with wind and issues can be addressed before winter (for most of US); unfortunately ran into early high wind season Commissioning Remote commissioning of installed units, troubleshooting of installed units 11/2014 1/2015 Commissioning delays due to lack of support from SCADA group in providing process values, primarily due to new turbine construction taking priority Some troubleshooting required on site by EDPR technicians after installs were complete 3

4 Lessons Learned Planning and Installation Retrofits can be very different than factory installs performed by turbine OEM s Potentially more flexibility than a standard OEM offering Likely less integration with the turbine, requiring active engagement from IT and SCADA groups to setup required communication and data transfer schemas CMS retrofits require cooperation between many departments within the company, resulting in a potentially complex matrix of responsibilities and support structures, including cross-platform (NA/EU) in some cases Engineering, Operations, Maintenance, IT, SCADA, Asset Management, Finance, Procurement, and Senior Management can all be stakeholders and may be required to support retrofits in some manner Anticipate slower install times during the first week or two of installs Accompany each crew to ensure all are performing the install to the same standards Come to group agreements/understanding on any grey areas of installation as soon as possible (ex. Whether to add service loops to the sensor cables), ideally utilizing a model turbine installation as a group Perform QA/QC s quickly behind installation crews (each one) to ensure high quality service When possible, have all IT and SCADA development work completed prior to installation to facilitate immediate commissioning of CMS 4

5 Summary Experiences and Early Results No major unexpected budget hits Installations, once begun, were completed on schedule and with no major issues Overall, commissioning was slow due to overloaded SCADA team, but finished quickly when all of EDPR IT/SCADA pre-work was complete 25 unique alarm reports have been issued thus far, as well as 1 escalation report, and 1 hardware report It should be noted that these gearboxes were all inspected via borescope in the summer of 2014, and all planned repairs completed prior to oil changes and CMS installation 5 new findings have been brought to light via CMS and internal follow-up inspections so far, with numerous inspections pending due to weather Software platform works as advertised with full access to all data In-house expertise dedicated to CMS is still needed for future monitoring, along with developing in-house procedures for cross-platform shared monitoring 5

6 Early Findings HS GS Bearing Failure BKV Report Report issued by BKV 11/10/2014 Escalation report issued by BKV 12/2/2014 Borescope Results Inspected by EDPR 11/11/2014 HS GS Bearing Axial Cracks NOTE: Previously inspected June 2014 with no findings HS bearings replaced 12/16/2014 6

7 Early Findings HS RS Bearing Failure BKV Report Report issued by BKV 1/5/2014 Borescope Results Inspected by EDPR 1/6/2015 HS RS Bearing Axial Crack & Pitting NOTE: Previously inspected July 2014 with no findings Planned for 2015 repair 7

8 Thank you! 8