achieving high reliability of complex advanced energy ...mr. abrams is a renowned expert in the...

Engineering Solutions for Success

PRESENTED BY:PRESENTED BY:SCOTT B. ABRAMS, P.E.SCOTT B. ABRAMS, P.E.

NOVEMBER 19, 2009NOVEMBER 19, 2009

ACHIEVING HIGH RELIABILITY OF ACHIEVING HIGH RELIABILITY OF COMPLEX ADVANCED ENERGY SYSTEMSCOMPLEX ADVANCED ENERGY SYSTEMS


WHO WE ARE

• AWARD-WINNING ENGINEERING COMPANY

• ESTABLISHED 1984

• GLOBAL PRESENCE

• 96% REPEAT CUSTOMER BASE

RECOGNIZED INDUSTRY LEADERRECOGNIZED INDUSTRY LEADER


WHAT WE DO

• ENSURE THE RELIABILITY AND SAFETY OF NEW AND EMERGING SYSTEMS AND PRODUCTS– SAFETY-CRITICAL– REVENUE-CRITICAL– MISSION-CRITICAL

• RELIABILITY AND SAFETY IMPROVEMENT INITIATIVES ON EXISTING LEGACY SYSTEMS AND PRODUCTS

• PROVIDE SOFTWARE DEVELOPMENT

• DEVELOP TURN-KEY TEST EQUIPMENT

WORK WITH DEVELOPMENT TEAMWORK WITH DEVELOPMENT TEAM


WHY COMPANIES DEPEND ONTHE OMNICON GROUP

ENHANCERESOURCES

SCHEDULERECOVERY

REDUCEOPERATING

COSTS

FOCUS ONCORE

BUSINESS

ACCESSTO WORLD

CLASSTALENT

INCREASEPROFIT

REDUCEPROGRAM

RISK

OMNICONADVANTAGE


• AWARD-WINNING COMPANY WITH AWARD WINNING ENGINEERS– HIGHEST NUMBER OF ENGINEERS NAMED

“RELIABILITY ENGINEER OF THE YEAR” BY THE IEEE– YEAR-AFTER-YEAR BUSINESS ACHIEVEMENTS– NUMEROUS TESTIMONIALS AND COMMENDATIONS

• EXTREMELY LOYAL CUSTOMER BASE– RELATIONSHIPS CONTINUING FOR OVER 25 YEARS– LONG TRACK RECORD SATISFYING

CUSTOMERS WITH A UNIQUE BLEND OF EXPERTISE,IMAGINATION ANDCUSTOMER-ORIENTEDSERVICE

WHAT SETS US APART FROM OTHER ORGANIZATIONS?


WHAT IS A RELIABLE SYSTEM?

• PERFORMS ITS INTENDED FUNCTION FOR THE REQUIRED DURATION WITHIN A GIVEN ENVIRONMENT (HIGH OPERATIONAL AVAILABILITY)

• ADDITIONAL BENEFITS– SYSTEM OPTIMIZED FOR RELIABILITY VERSUS

PERFORMANCE, COST & NET REVENUE– LOWERS OPERATING COSTS– ACHIEVES CUSTOMER

EXPECTATIONS


BATHTUB CURVE


OPTION 1 SCALEABLE SOLAR ARRAY FIELD

TRANSFORMER

12.4KV OUTPUT

TRANSFORMER

12.4KV OUTPUT

12.4KV, 3PHCOLLECTION

LINES(4.0 MW)

TRACKERS/CONCENTRATORS

MONITORS ANDCONTROL

COMBINERBOXES DISCONNECTS

2,496 SOLARPANELS

(104 STRINGSOF 24 PANELS)

480V 3PH,500KW

INVERTER

2,496 SOLARPANELS


480V 3PH,500KW

INVERTER

2,496 SOLARPANELS


480V 3PH,500KW

INVERTER

2,496 SOLARPANELS


480V 3PH,500KW

INVERTER

2,496 SOLARPANELS


480V 3PH,500KW

INVERTER

2,496 SOLARPANELS


480V 3PH,500KW

INVERTER

2,496 SOLARPANELS


480V 3PH,500KW

INVERTER

2,496 SOLARPANELS


480V 3PH,500KW

INVERTER


TRANSFORMER

12.4KV OUTPUT

TRANSFORMER

12.4KV OUTPUT


OPTION 2 SCALEABLESOLAR ARRAY FIELD

TRANSFORMER

12.4KV OUTPUT

TRANSFORMER

12.4KV OUTPUT

12.4KV, 3PHCOLLECTION

LINES(4.0 MW)


MONITORS ANDCONTROL


4,992 SOLARPANELS


480V 3PH,1.0MW

INVERTER

DISCONNECTSCOMBINER

BOXES

4,992 SOLARPANELS


480V 3PH,1.0MW

INVERTER

4,992 SOLARPANELS


480V 3PH,1.0MW

INVERTER

4,992 SOLARPANELS


480V 3PH,1.0MW

INVERTER


RELIABILITY COMPARISON QUESTIONS

• HOW DOES DECREASE IN EQUIPMENT QUANTITY, AFFORDED BY INCREASE IN EQUIPMENT POWER, EFFECT RELIABILITY (MTBF, MTBCF, MTBMA)?– HOW DOES 1MW INVERTER COMPARE TO 500KW

INVERTER?– HOW DOES 2MW TRANSFORMER COMPARE TO 1MW

TRANSFORMER?

• HOW DOES DIFFERENT SYSTEM ARCHITECTURES EFFECT INTERCONNECT RELIABILITY AND GRACEFUL DEGRADATION?

• WHAT IS TIME & COST TO CORRECT FAILED EQUIPMENT (SPARES AVAILABILITY, MTTR, LOGISTICS DELAY TIME, LOST REVENUE)?


BENEFIT OF REDUNDANCY

Reliability of One Unit

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60

Time (months)

R(t

) & P

erce

nt Im

prov

emen

t

Single Unit

1 of 2 Units Rqd

Improvement


BENEFIT OF REDUNDANCY WITH GRACEFUL DEGRADATION

Reliability of Four Units

0

20

40

60

80

100

120

140

160

0 10 20 30 40 50 60

Time (months)

R(t

) & P

erce

nt Im

prov

emen

t

4 Units

4 of 5 Units Rqd

Improvement

100% Improvement

after 40 Months of Operation

Reliability near 100% if failed unit repaired

before next unit fails


ACHIEVING A COST EFFECTIVERELIABLE SYSTEM (1 OF 3)

• KNOW THE DESIGN & ENVIRONMENT REQUIREMENTS• DEVELOP SYSTEM & EQUIPMENT SUCCESS CRITERIA’S• FLOW DOWN REQUIREMENTS • DEVELOP RELIABILITY MODELS• PERFORM/SUPPORT TRADE-OFF STUDIES• IDENTIFY CRITICAL ITEMS• DERATE EQUIPMENT & COMPONENTS• IDENTIFY LIMITED LIFE ITEMS• NEGOTIATE WITH EQUIPMENT SUPPLIERS

– WARRANTY – MANUFACTURER RESPONSE TIME– UP-TIME GUARANTEE

• PARTICIPATE IN FORMAL DESIGN REVIEWS• ACCOMPLISH WORST CASE ANALYSES



• PREDICT EQUIPMENT & SYSTEM RELIABILITY• APPLY PHYSICS OF FAILURE• KNOW YOUR DISSIMILAR METALS• UNDERSTAND PROPERTIES OF MATERIALS• PERFORM FAILURE MODE AND EFFECTS ANALYSIS• IDENTIFY SINGLE POINT FAILURES• DOCUMENT COMPENSATING PROVISIONS• DEVELOP FAULT/SUCCESS TREES• ASSESS DIAGNOSTICS CAPABILITIES• DEVELOP TROUBLESHOOTING TREES• ASSESS FEASIBILITY & BENEFITS OF PROGNOSTICS• DETERMINE IF COMMON CAUSE FAILURES EXIST• ASSESS EFFECTS OF SHIPPING & INSTALLATION• DETERMINE OPTIMUM ON-SITE SPARES



• PERFORM RELIABILITY TESTING• PERFORM MAINTAINABILITY ANALYSIS • OPTIMIZE MAINTENANCE CONCEPT• DEVELOP SUPPORTABILITY PLAN• CONSIDER HUMAN FACTORS EFFECT ON RELIABILITY• IDENTIFY, ELIMINATE & DOCUMENT SAFETY HAZARDS• DEVELOP PREVENTIVE MAINTENANCE ACTIONS• MAINTAIN LIST OF SCHEDULED MAINTENANCE TASKS• MAINTAIN LIST OF DEFERRED MAINTENANCE ITEMS• DEVELOP CORRECTIVE MAINTENANCE PROCEDURES• PERFORM FAILURE ANALYSIS• MAINTAIN FAILURE REPORTING & CORRECTIVE ACTION

SYSTEM• SHARE LESSONS LEARNED WITH KEY SUPPLIERS


CONCLUSION

• APPLICATION OF RELIABILITY PRINCIPLES & PRACTICES TO ADVANCED ENERGY SYSTEMS– HELPS CONTROL PROJECT RISK– MINIMIZES COSTLY BAND-AIDS– INCREASES LIFE OF INVESTMENT– INCREASES POWER OUTPUT– MINIMIZES LIFE CYCLE COSTS– INCREASES NET PROFITS– INCREASES LENDER & CUSTOMER

SATISFACTION

WILL PAY FOR ITSELF!WILL PAY FOR ITSELF!


CONTACT INFORMATION

SCOTT B. ABRAMS, [email protected] X304

THE OMNICON GROUP INC40 ARKAY DRHAUPPAUGE, NY 11788WWW.OMNICONGROUP.COM

Scott B. Abrams is President and CEO of The Omnicon Group, an award-winning engineering company recognized for ensuring the reliability of new and emerging systems and products. Since 1984, Mr. Abrams and The Omnicon Group have worked with technology companies throughout the world to analyze and improve the reliability and safety of their products, to develop robust systems and software, and to provide comprehensive test engineering services.

Mr. Abrams is a renowned expert in the reliability field and was dubbed “Mr. Reliability” by the Long Island Business News and “The Gizmo Doctor” by the New York Times. His most proud citation is the “Reliability Engineer of the Year” award he received from his peers at the IEEE Reliability Society.

Mr. Abrams received his B.E. in Electrical Engineering from Stony Brook University and a M.S. in Electrical Engineering from Polytechnic University. He is a licensed Professional Engineer in New York State.

achieving high reliability of complex advanced energy ...mr. abrams is a renowned expert in the...

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