optimisation of maintenance strategies for offshore wind farms
TRANSCRIPT
Working together for a safer world
Optimisation of maintenance strategies for offshore wind farms
knowledge based operations integrity using varied data sources
Lloyd’s Register Energy
Lloyd’s Register Today – A Group Overview
• Celebrated our 250 year anniversary in 2010
• Some 8,000 employees serving 50,000 clients
• Offices in 245 cities and towns globally
• Over 100 companies
• Four business divisions: • Marine
• Energy
• Management Systems
• Transportation
• 2012/13 turnover £920m
• A Registered Charity
• Supports education through the Lloyd’s RegisterFoundation (LRF)
Renewables
Example applications:
• Off-shore wind
• Wave and tidal / marine renewables
• Carbon capture and storage
Example services:
• IEC 61400 – 22 certification
• Project certification
• Wind turbine type certification
• Manufacturing surveillance
• PAS 55, HSE and IV&V
• Measurement and failure investigation
Lloyd’s Register Energy
How is a windmill kept running reliably and cheaply?
Lloyd’s Register Energy
Dynamic software for reliability improvement
Knowledge Based Asset Integrity (KBAITM) The 4th Generation Approach
4
Data
Information
Knowledge
Reactive
• Fix it when it breaks
Preventive
• Maintain it before it breaks
• Regular, time-based maintenance routines
• Used by majority of organisations
Proactive
• RCM • Expert judgment
• Systematically monitor KPIs
• Condition monitoring
• Enterprise systems/CMMS
Risk Based
• Knowledge codified in web-based system
• Data linked directly to existing CMMS
• Feedback of key maintenance data
• Database analysis to update component reliability tables
• Workers managing knowledge, not knowledge retained by workers
Lloyd’s Register Energy
Why this approach?
• Understand the turbine – normal operation
– failure mechanisms
– failure probability
– failure consequences
• Optimise maintenance costs
• Improve critical asset availability
• Analyse future risks and maintenance costs
• Provide justification for equipment renewal and repairs
Lloyd’s Register Energy
Why this approach? – crisis resilience theory
Capability and Performance
Time
Normal variation in performance
Harm
impact on performance
response / recovery time
recovery
diminishment
time to discover
with thanks to Doug Owen, LR Consulting – Human Factors
major failure of turbine
Lloyd’s Register Energy
Why this approach? – crisis resilience theory
Capability and Performance
Time
Normal variation in performance
Harm
impact on performance
response / recovery time
recovery
diminishment
time to discover
with thanks to Doug Owen, LR Consulting – Human Factors
prognostic horizon - time to predict
major failure of turbine
Lloyd’s Register Energy
Why this approach? – crisis resilience theory
Capability and Performance
Time
Normal variation in performance
Harm
Recovery
extend prognostic horizon, avoid failure altogether
1
with thanks to Doug Owen, LR Consulting – Human Factors
sched
uled
repair
Lloyd’s Register Energy
Why this approach? – crisis resilience theory
Capability and Performance
Time
Normal variation in performance
Harm
Recovery
Reduce the time to
discover / react
2
with thanks to Doug Owen, LR Consulting – Human Factors
Lloyd’s Register Energy
Why this approach? – crisis resilience theory
Capability and Performance
Time
Normal variation in performance
Harm
Reduce the Response / Recovery time
Recovery
3
with thanks to Doug Owen, LR Consulting – Human Factors
Lloyd’s Register Energy
Why this approach? – crisis resilience theory
Capability and Performance
Time
Normal variation in performance
Harm Reduce the
impact of the disturbance
Recovery
4
with thanks to Doug Owen, LR Consulting – Human Factors
Lloyd’s Register Energy
prognostic horizon - time to predict
Why this approach? – crisis resilience theory
Capability and Performance
Time
Normal variation in performance
Harm
Impact on performance
Response / Recovery time
recovery
diminishment
Time to discover
major failure of turbine
Lloyd’s Register Energy
Decision-making based on knowledge
knowledge
Lloyd’s Register Energy
Decision-making based on knowledge
database of historical reliability
statistics
knowledge CMS
SHM
experience of manufacturer,
O&M technicians, wind farm owner
• technicians’ logs — maintenance tasks feedback — remedial action undertaken
• spare parts inventory
Lloyd’s Register Energy
Knowledge-Based Asset Integrity
Likelihood of Failure (events per year)
• Equipment type and items used
• Age, usage, environment, etc
• Equipment condition (based on visual inspection, past maintenance, failure causes and condition monitoring, etc)
Consequence of Failure (impact per event)
• Disruption to business
• Environmental + Health and Safety impacts
• Reputation – Public/Political
Consequence Ranking
A B C D E
HIGH
MED HIGH
MEDIUM
LOW
1
2
3
4
5 Pro
bab
ility
Ran
kin
g Maintenance and Inspection
Task Plan optimised to the asset and the business (£ impact per event)
• Includes industry best practices
• May increase or decrease current maintenance
Lloyd’s Register Energy
Risk matrices – common basis for comparison of risk
Lloyd’s Register Energy
Risk profile of offshore wind farm
substation offshore substations array cabling and interconnectors
wind turbines
Lloyd’s Register Energy
Risk matrices – common basis for comparison of risk
Example wind turbine – risk units wind turbine
rotor blade blade root bearing hub pitch system – hydraulic pitch assemblies pitch system – hydraulic power pack pitch system – hydraulic accumulator pitch system – hydraulic pipework slip rings pitch gear lubrication system pitch bearing seals
drivetrain rotor lock system – rotor lock pins rotor lock system – electro-mechanical actuator(s) gearbox – gearbox casing/ structure gearbox – lubrication system gearbox – mounts high speed shaft generator coupling mechanical shaft brake generator
electrical system power converter switchgear
transformer yaw system
electro-mechanical yaw drive assemblies electrical drives (power electronics) slewing ring/ ring-gear assemblies hydraulic yaw brake assemblies – brake calipers hydraulic yaw brake assemblies – hydraulic pipework hydraulic yaw brake assemblies – hydraulic power pack
control system sensors electrical cabinets
nacelle anemometer wind vane access: platforms, ladders, safety systems
tower cylindrical or conical sections bolts brackets, cables, platforms, ladders, lift assembly
substructure transition piece monopile foundation
Lloyd’s Register Energy
Initial configuration of software for wind farm O&M planning
• based on statistics published by Reliawind project
Lloyd’s Register Energy
Risk profile update using measured data
• operational data – geographical representation
Lloyd’s Register Energy
Initial configuration of software for wind farm O&M planning
Lloyd’s Register Energy
Technical expertise applicable to asset integrity service
bearing analysis
Operational Modal Analysis
Experimental Modal Analysis
gearbox RCA
sensors
data acquisition units
signal processing software
analysis of auxiliary frame
new configuration of CM after system refurbishment/ replacement/ upgrade
Lloyd’s Register Energy
Program for optimising operations and maintenance
Increase availability, increase production, increase revenue
Reduce turbine visits, vessel costs, delays, downtime
Reduce spares count, delays prepare better for turbine visits: correct spares, correct tooling, trained technicians
Schedule major repairs for appropriate weather windows and periods of low production
Eliminate excessive or unnecessary turbine visits, combine minor repairs into fewer visits
Understand turbine operation and normal turbine behaviour
Retain, develop and deepen knowledge using common platform
Extend prognostic horizon
Lloyd’s Register and variants of it are trading names of Lloyd’s Register Group Limited, its subsidiaries and affiliates. Copyright © Lloyd’s Register EMEA. 2015. A member of the Lloyd’s Register group.
Working together for a safer world
Mark Spring Senior Wind Turbine Specialist Renewable Energy - Wind T +44 (0)207 423 1844 E [email protected] Lloyd’s Register EMEA 71 Fenchurch Street, London EC3M 4BS