World Class Windturbine Maintenance Project

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World Class Windturbine

Maintenance Project

Ir. Johan Prinsloo, Technical Director

A presentation by IMS International

Your partner in Integrated Maintenance & Asset Management Solutions

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Introduction

Responding to Dutch World Class Maintenance ambition

Taking the engineering & consulting services of KEC and Filanet one step further

Participants of WCWM

project

From strategy up till operational excellence

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2007 1985

1

HIGHER EDUCATION

University of Pretoria BEng Electronic Engineering BEng (Hons) Electronic Engineering

2011 1987

1979 2009

AIR FORCE SECURITY OFFICER

South African Defence Force (Compulsory Military Duty)

MINING

Rope testing, Maintenance Management solutions

DEFENCE

Naval, Army, Air Force projects: Advanced Weapon Integration, Avionics , GBADS, Submarine

consoles, Logs Equipment

RAIL

Integrated Train Condition Monitoring Systems, Vehicle Identification systems/Tracking,

Locomotive Computer systems

SPACE

Satellite interface design, Launch vehicle interface design

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 • …….. 1982 TECHNICAL DIRECTOR/BUSINESS DEVELOPMENT INDUSTRIAL Maintenance Management Systems, Condition Based

Monitor Systems CO-FOUNDED ANSYS ANSYS LISTED ON THE JHB STOCK EXCHANGE

PRETORIA

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Control room

Maintenance management

& monitoring

Field support

Knowledge management

Consistent data collection

Digitized Maintenance Goals

Asset based procedures

Logistics, resources, spares &

tools optimization

Track & trace

Maintenance management

dashboard

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Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.

FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS)

MMS

SERVER PDA RFID

Tag

ASSET OWNER

HUB

Radio Frequency Uses Cellular Network (3G, GPRS),

Telephone Modem if cellular network is not available, or satellite communication MMS WEB PORTAL Reporting Planning Controlling Scheduling Metrics ASSET OWNER SERVER

Asset Owner uses MMS as Single Integrated Predictive Maintenance Management Solution

HUMS Automatic Measuring Points Automatic Sensors Condition Monitoring Points

Wireless, Radio Frequency, etc.

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 real-time tracking (location) within the HUMS sensor range.

SENSORS

MMS

Maintenance tasks, information on logistics, spare parts and tools

Routing, maintenance procedures, safety, environmental instructions

Just in time , relevant technical, routing and logistics information Remote support

Feed back of maintenance data, completed tasks, inspection data, pictures, parameters, data of remote sensors Plan Do Check Act Optimize maintenance based on consistent, reliable data. Incident and problem management Monitoring of maintenance and operations Schedule maintenance tasks

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FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS)

Digitized into 345 consistent tasks and 3 scheduling levels

DELTA WT MAINTENANCE AND INSPECTION SCHEDULES FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS) WEB PORTAL

Delta OLAZ II Live Pilot Tests performed in Q4 2012 & Q3/Q4 2013

by Delta technicians Owner Inspection for

Kreekrak Q1 2014 Delta / Oliveira

Control Room / Management Dashboard

Filanet supplied Handheld

Knowledge

management

Knowledge

management

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FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS)

• WT (OLAZ II – Vestas V47) Maintenance / Inspection Schedules fully digitized and available through the web-based 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/Q4 2013 and Q1 2014 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

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FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS)

Completed Tasks, shows status (Green = no issues, Red = Issues to be resolved)

See next slide for detail of Task ID 10543

MMS Web Portal – Screenshot 1 (shows status of high level scheduled tasks)

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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

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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.

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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.

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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.

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FILANET RELIABILITY CENTERED MAINTENANCE (RCM) – SLIDE 2/3

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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.

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Further development towards asset

& maintenance management

solutions by IMS International

More information during the

afternoon session

15 ASSET & MAINTENANCE MANAGEMENT SOLUTIONS

IMMS Maintenance Manager

Asset Management Specialist Edition V1.0 Welcome J. Prinsloo

Welcome J. Prinsloo

IMMS Android App

Asset Management Specialist Edition V1.0 Welcome J. Prinsloo