current trends of wind farm maintenance
TRANSCRIPT
© Fraunhofer IWES
IN EUROPE
CURRENT TRENDS OF WIND FARM MAINTENANCE
Dipl.-Ing. M.Sc. Stefan Faulstich Dipl.-Wi.-Ing. P. Lyding, M.Sc. Paul Kühn Fraunhofer Institute for Wind Energy and Energy System Technology (IWES)
© Fraunhofer IWES
The Fraunhofer Society in Germany 60 Institutes at 40 locations
München
Holzkirchen
Freiburg
Efringen- Kirchen
Freising Stuttgart
Pfinztal Karlsruhe Saarbrücken
St. Ingbert Kaiserslautern
Darmstadt Würzburg
Erlangen
Nürnberg
Ilmenau
Schkopau
Teltow
Oberhausen
Duisburg
Euskirchen Aachen
St. Augustin
Schmallenberg
Dortmund
Potsdam Berlin
Rostock
Lübeck Itzehoe
Braunschweig
Hannover
Bremen
Bremerhaven
Jena
Leipzig
Chemnitz
Dresden
Cottbus Magdeburg
Halle
Fürth
Wachtberg
Ettlingen
Holzen
Kassel
Kassel
Bremerhaven
Formerly: Fraunhofer Center for Wind Energy and Maritime Engineering CWMT in Bremerhaven Institute for Solar Energy Technology ISET in Kassel
© Fraunhofer IWES
Motivation Starting Point: Modern wind turbines achieve high availability
Number of faults cause unplanned downtimes high maintenance efforts and costs
Offshore: drop of availability expected
200
6/2
00
7
200
7/2
00
8
Barr
ow
© Fraunhofer IWES
Scientific Measurement and Evaluation Program („250 MW Wind‚ (1989-2006))
193.000 monthly operation reports and 64.000 Incident reports from 1.500 wind turbines
1983
2010
Failure Database: WMEP
Reliability
Technology development
Learning curves
© Fraunhofer IWES
Failure Database: WMEP
© Fraunhofer IWES
Failure Database: WMEP
© Fraunhofer IWES
Maintenance organisation
Wind Energy Conventional power plants
General
Structure decentralised arranged and centralised
Experience low decades
Operating conditions
operation unmanned, fully automated manned, semi-automatically
Condition assessment exclusively on sensors Senses and experience of staff
External conditions Changing and extreme conditions Constant conditions by enclosing
Load Fluctuating power output and imposed loads Quasi-stationary operation
Maintenance organisation
Staff Often, little own qualified staff Skilled and trained service personnel
Documents deficient, according to the manufacturer's good will contractually agreed part of the delivery
Process optimized to maximize profits from the manufacturer optimized for LCC
Documentation deficient according to the Group's internal requirements
Standardization insufficient, cycling is often reinvented Established standard culture
Information No feedback of experience Evaluating long-term findings
© Fraunhofer IWES
Maintenance organisation
Maintenance
Strategy
• reactive • time based • condition based • reliability based
Event
• failure • fault • inspection • repair
Documentation
• subassembly • cause • time steps • cost
Archiving • core data (RDS-PP) • in-service data • event data (EMS)
Analysis • MTBF, MTTR • weak points • expenses • life cycle cost
Planning • improvement • consolidation • interval opt. • responsibility
Accurate, detailed documentation Consistent naming of components Unified description of irregularities and activities
Design • verification • modification
Lacking of a closed maintenance loop
Use of operating experiences
© Fraunhofer IWES
Maintenance strategies The reliability based maintenance tries to find the right time for maintenance measures through analysing a broad data base filled with experiences from the past
The condition based maintenance strategy tries to find the optimum point in time for carrying out the required maintenance actions by monitoring the current state of a specific component
Preventive maintenance strategies try to react before a failure occurs
With the cyclic maintenance strategy components of the wind turbine will be inspected and maintained cyclically, e. g. on semi annual intervals
It can be distinguished between reactive and preventive maintenance strategies
Within the break down maintenance strategy the system will be operated until a major failure of a component will result in a shut down
Maintenance strategies
Reactive Maintenance
Preventive Maintenance
Break down
Cyclic Condition
based Reliability
based
© Fraunhofer IWES
Value of Experience
12
34
56
7
8
9
10
1
2
3
4
5
0,00,20,40,60,81,01,21,41,61,82,02,22,42,62,83,03,23,43,63,84,0
mea
n a
nn
ua
l fa
ilu
re f
req
ue
nc
y
year of operation year of
production
Optimization of intervals
Optimization of strategies
LCC prediction
Constitute priorities
Source: IZP Dresden
© Fraunhofer IWES
Appropriate Failure Statistics
Year of operation??? Turbine type???
For differential analysis distinctions regarding size, technical concepts, site conditions, etc. must be made
WMEP-DB
1453 WEAs
>3. year of product ion
527 WEA
1.-3. year of product ion
926 WEA
P<500kW
783 WEA
P≥1000kW
16 WEA
500kW≤P<1000kW
127 WEA
asynchronous
584 WEA
synchronous
199 WEA
Coast line
102 WEA
highlands
33 WEA
lowlands
64 WEA
© Fraunhofer IWES
Establishing a common database
The project Offshore~WMEP is a follow-up project to the onshore wind energy monitoring program ‘Scientific Measurement and Evaluation Program’ (WMEP) and accompanies the offshore wind energy deployment in Germany
Funded by the German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety
© Fraunhofer IWES
Conclusions
Potential for availability improvement and for reducing maintenance effort exists
Clear trend from reactive to preventive measures
Use of operating experience essential
Common database needed due to parameter diversity
Different concepts necessary
Overall data structure
Standards and definitions (e.g. RDS-PP)
Accessibility of information
Several groups and projects deal with the topic of establishing a common database
© Fraunhofer IWES
Outlook
TASK 11 IEA Wind: BASE TECHNOLOGY INFORMATION EXCHANGE Topical Expert Meeting #65 (March 30-31, 2011) on ‚INTERNATIONAL STATISTICAL ANALYSIS ON WIND TURBINE FAILURES‛
IEA-Task-proposal ‚Reliability Data - Standardization of data collection for wind turbine reliability and maintenance analyses‛
© Fraunhofer IWES
Thank you for your attention
Dipl.-Ing M.Sc. Stefan Faulstich [email protected] Reliability & Maintenance strategies R&D Division Energy Economy and Grid Operation Fraunhofer Institute for Wind Energy and Energy System Technology IWES Königstor 59, 34119 Kassel