OPERATION AND MAINTENANCE Levent İshak Service Manager, Vestas Turkey IWPC 2015-Istanbul- April 2015
If your new car drove as much as a wind turbine, it would have to be scrapped after 6 months*. ) The average car is scrapped after 4500 hours of operation. This equals 6 months Operation of a wind turbine (www.dkwind.dk).
A Challenging Environment Wind Industry s Service and Operational Risks Turbine performance during optimum conditions Performance management expertise Budgeting for unplanned maintenance events Spare parts access & availability and supply chain reliability Shortages in skilled workforce Safe and environmentally friendly footprint for O&M IWPC 2015-Istanbul- April 2015
Failure rate Customer s Cost of Energy Reliability Curve Early life failures Vestas warranty Service Offerings Technical Support Knowledge management Re-engineering/part reliability Predictive Diagnostics Highly skilled & trained local service Stable reliability Vestas offering Weibull out d o w n Decreased Part Customer C Part Risk B Part A Weibull Increased failures Weibull Improved reliability/productivity Reduced EOL part cost Customer Risk Weibull Vestas Service Value: Productivity & Lower Cost Years IWPC 2015-Istanbul- April 2015
Vestas Active Output Management (AOM) Service Philosophy Our commitment to helping you achieve maximum ROI. Superior service and certainty through: 40 GW currently serviced under an AOM Contract the RIGHT PEOPLE, supported by the RIGHT INTELLIGENCE, using the RIGHT OPERATIONS AND MAINTENANCE PLAN, executed with the RIGHT INFRASTRUCTURE, maintaining a strong PARTNERSHIP with our customers backed by performance guarantees 5 AOM IWPC 2015-Istanbul- Active Output April Management 2015
The Right PEOPLE 5500 Advanced turbine technology and safe operations require competent personnel. VESTAS TECHNICIANS arrive well prepared, supported by a large team & knowledge base. You benefit from: employed worldwide to ensure superior turbine operation CERTIFIED TRAINING SAFETY VALUES FIELD EXPERIENCE Training certified by: 6 Certified technicians (4 levels) with the right knowledge and skills Industry leader in safety and training AOM IWPC 2015-Istanbul- Active Output April Management 2015 Mandatory Safety Walks by management Technicians empowered to stop work if something appears unsafe or someone is at risk Safety First is the primary value driver for Vestas service technicians Highest HSE standards, OHSAS 18001 certified R&D optimised diagnostics and maintenance strategy Support from technical help desk LEAN problem solving techniques
The Right INTELLIGENCE Vestas builds predictive intelligence through research, monitoring and field experience to maximise the output using different systems. VESTAS PERFORMANCE AND DIAGNOSTICS CENTRE (VDPC) monitors over 21 000 turbines amounting to almost 40 GW 1/ 6 of the world s installed wind capacity is monitored by Vestas DATA ANALYSES VTM Vestas Turbine Monitoring CMS Condition Monitoring System PREDICTIVE CONDITION BASED MAINTENANCE Assessing the "health" of a machine by analysing measured signals Assessments integrated into work planning Analysing more than 130 signals from heat sensors Detecting potential failures and outliers Estimating the time of failure optimised planning of maintenance activities In-house ISO Certified Vibration Engineers Assessments integrated into work planning 7 AOM IWPC 2015-Istanbul- Active Output April Management 2015
The Right OPERATIONS and MAINTENANCE PLAN 14 + Maintenance operations and planning are executed synchronously by prevention through prediction. years of expertise in 24/7/365 surveillance Vestas Turbine Watch provides 14+ years expertise in of 24/7/365 SURVEILLANCE Performance deviations in the fleet are identified to INITIATE OPERATIONS activities at the RIGHT TIME MONITOR IDENTIFY & INITIATE Preventive Maintenance Maintenance strategy Predictive Maintenance Corrective Maintenance LEARN & IMPROVE PLAN & REPAIR Findings used to provide RELIABLE PERFORMANCE & OUTPUT MANAGEMENT Planning of maintenance based on Vestas weather forecast to MAXIMIZE PRODUCTION 8 AOM IWPC 2015-Istanbul- Active Output April Management 2015
The Right INFRASTRUCTURE Synchronized service support structure. GLOBAL SPARE PARTS AND REPAIR 24/72 hours delivery time worldwide of spare parts / main components Global delivery, logistics and sourcing network, local warehouses Certainty of quality, supply and control of cost Repair capabilities for generators, gearbox and other components TECHNOLOGY HOTLINE AND PRODUCT UPGRADES 1 st Level Support 2 nd Level Support Technology R&D 24/7 surveillance center/hotline accessible through email or phone High expert knowledge available at country or region level Open normal business hours, accessible through 1 st level support Access to unique OEM technical expert knowledge Failure analysis & proactive engineering upgrades to enhance performance CUSTOMISED ERP AND PROPRIETARY FAQ ERP Work Order and Guides for fixing issues, list of necessary spare parts and list of other maintenance tasks Efficient service operations and strategic maintenance planning 9 AOM IWPC 2015-Istanbul- Active Output April Management 2015
The Right PARTNERSHIP Maximizing the partnership through ongoing communication. the the RIGHT RIGHT the RIGHT PARTNERSHIP EQUIPMENT PEOPLE 8 Vestas Training Centers worldwide CUSTOMER PORTAL VESTAS CUSTOMER PORTAL contains documentation, news, alerts and monthly progress reports for all customer projects in one place BUSINESS REVIEWS BUSINESS REVIEWS at the customer account level to discuss performance and technical issues CERTIFIED TRAINING Certified CUSTOMER TRAINING on safety and operation to empower customers to manage their assets 10 AOM IWPC 2015-Istanbul- Active Output April Management 2015
IS THIS ENOUGH?
Data Driven Optimisation Vestas PowerPlus IWPC 2015-Istanbul- April 2015
200901 200904 200907 200910 200913 200916 200919 200922 200925 200928 200931 200934 200937 200940 200943 200946 200949 200952 201002 201005 201008 201011 201014 201017 201020 201023 201026 201029 201032 201035 201038 201041 201044 201047 201050 201101 201104 201107 201110 201113 201116 201119 201122 201125 201128 201131 201134 201137 201140 201143 201146 201149 201152 201203 201206 201209 201212 201215 201218 201221 201224 201227 201230 201233 201236 201239 201242 201245 201248 201251 201302 201305 201308 201311 201314 201317 201320 201323 201326 201329 201332 201335 201338 201341 201344 201347 201350 LPF [%] Good Strategic focus on service and after sales business Vestas is committed to improving and growing its service and after sales offering After sales is an integral part of Vestas growing service business Focused on upgrades and solutions that increase performance and reduce operating cost and improve efficiency Capturing the value of Vestas R&D and Performance & Diagnostics Centre to improve turbines already installed in the field 6 5 4 3 2 1 0 Lost Production Factor @ Vestas IWPC 2015-Istanbul- April 2015
Vestas is using siting resources throughout the project life cycle Understanding the climatic conditions on a site is critical Is this a good site for wind turbines? Can we optimise these turbine? IWPC 2015-Istanbul- April 2015
Data as decision drivers start with the best, not with a guess! Vestas is using siting resources throughout the project life cycle Unique Global Climate Library + 26.000 turbines online + More than 52.000 turbines installed in 73 countries + Close to 4000 met masts + Performance and diagnostics data Intelligent database and super computer resources IWPC 2015-Istanbul- April 2015
Super Computer Facilities Compute: 1.306 compute nodes 2.612 Intel X5670 CPUs 15.672 X5670 cores Storage: 2.400TB 3rd largest industrial HPC, PiBs when installed in 2011 Wind Energy O&M Forum - Hamburg - January 2015
From Global to Local......from Climate to WTG Performance IWPC 172015-Istanbul- From Climate April to Capital 2015
The power of a historical climate library A unique library of climate data down to the lowest atmospheric levels Mesoscale models provide us with a consistent worldwide coverage of more than 100 climatic variables. Base resolution 3 x 3 km globally. Data available, hour by hour, from Jan. 2000 to present Combined with 26.000 turbines online and thousands of wind measurements Data Driven Decisions IWPC 2015-Istanbul- April 2015
Powerful match Site optimisation is combining actual production data with historical mesoscale data Vestas PowerPlus wind power plant optimisation is climate dependent Actual production data with onsite measurements is used with mesoscale data for increased accuracy The result is the best possible understanding of the climatic reality on site IWPC 2015-Istanbul- April 2015
Data drives decision-making Vestas is evaluating loads and AEP potential turbine by turbine down to the component level Upgrade-specific load models ensure that optimisation is done in compliance with the original design loads envelope Load exceedances are highlighted and mitigated Vestas uses a proprietary, DNV-certified tool Vestas Site Check! IWPC 202015-Istanbul- April 2015
When it comes to optimising your wind power plant don t take chances trust the experts with the data! IWPC 2015-Istanbul- April 2015
Vestas PowerPlus - Production Improvement Solutions Optimised performance of wind turbines and increased annual energy production Vestas PowerPlus is the newly launched platform for production improvement solutions developed by Vestas and dedicated to the aftermarket. It currently consists of the following solutions: Power Uprate Extended Cut Out Aerodynamic Upgrades Beyond that, Vestas PowerPlus is a mindset within the organization. It embodies our commitment to constantly improve our existing turbines. Up to 5% Increased annual energy production* Site-specific optimization of control parameters and aerodynamic performance Building on extensive wind turbine knowledge and industry-leading R&D IWPC 2015-Istanbul- April 2015 *Actual AEP increase depends on turbine type and site conditions
Power Uprate Increase production by fully utilising available load margins Increase annual energy production by up to 4% Model Power Curve of up-rated V90-1.8/2.0MW Increase nominal power of V82-1.65MW to 1.8MW and V90/100-1.8MW up to 2.0MW Optimise use of available load margins within certified design loads envelope Use Wind Sector Management for optimal performance on climatically challenging sites Turbine- and site-specific loads and AEP analysis performed by Vestas Example of optimised utilisation of load margins Optimise energy production on interconnect grid limited site using PPC to manage output Combine Power Uprate with Aerodynamic Upgrades (V82, V90, V100) and Extended Cut Out (V100) IWPC 2015-Istanbul- April 2015 *Actual AEP increase depends on turbine type and site conditions
Extended Cut Out Capture the full potential of strong winds by optimising cut out and re-cut in settings Increase annual energy production by up to 2%* Extend cut out and re-cut in wind speeds of V100 up to 25m/s and V90-3MW up to 30m/s Optimise use of available load margins within certified design loads envelope Turbine- and site-specific loads and AEP analysis performed by Vestas Extended cut out on model power curve Reduce abrupt stops due to high wind, minimizing stress on drivetrain parts Example of production gains on V90-3MW No increase in name-plate rating full benefit even on interconnect grid limited sites Combine Extended Cut Out with Power Uprate on V100, and Aerodynamic Upgrades on V90 and V100 turbines IWPC 2015-Istanbul- April 2015
LAST BUT NOT LEAST HEALTH SAFETY ENVIRONMENT Wind Energy O&M Forum - Hamburg - January 2015
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