Capacity building 2010 day 3 lessons

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Capacity Building in the Field of Wind Energy, Stage II …

Capacity Building in the Field of Wind Energy, Stage II
29 March - 2 April, 2010

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  • 1. rned L ea from ….. so nsL es
  • 2. Site characteristicsDescribed by site topography andsite climate change.To calculate the effects of sitetopography on the wind power, itis necessary to describe the natureof the site topography i.e.roughness, Obstacles, andorography, to understand theeffects of each parameter on thewind power.Climate changeB= ρRTP1 =0.5 X ρ1 X U3
  • 3. Zafarana Wind Farm is located 120km south of Suez on the Red Sea.
  • 4.  Zafarana site Flat area 20 km along sea cost, Average wind speed 8.5 m/s Turbulence intensity lower than 7%, Summer windy - prevailing wind direction bounded in Narrow zone
  • 5. Machine technology Utility-scale wind turbines for land-based wind farms come in various sizes, with rotor diameters ranging from about 50 meters to about 90 meters, and with towers of roughly the same size. A 90- meter machine. with a 90-meter tower would have a total height from the tower base to the tip of the rotor of approximately 135 meters. Offshore turbine designs now under development will have larger rotors—at the moment, the largest has a 110-meter rotor diameter—because it is easier to transport large rotor blades by ship than by land. Small wind turbines intended for residential or small business use are much smaller. Most have rotor diameters of 8 meters or less and would be mounted on towers of 40 meters in height or less.
  • 6. Machine technology
  • 7. Wind Farm Arrangement of arrays inside wind farm is called (micro-siting) and it is one of the main factors that improve the wind farm performance because of the following: Reduce wake interaction between turbines each other to avoid: - fatigue damage. - Reduce stress on movement parts ( yaw system, and blades of turbines) Minimize required area maximize energy production of wind farm.
  • 8. Operation & Maintenance
  • 9. Zafarana  ‫ﺻﯿﺎﻧﺔ دورﯾﺔ‬TIME BASED MAINTENANCE H.R.OF TIME BASED MAINTENANCE FAULTS& MANF. PLAN NO FEED BACK FAILURE • ‫ﺻﯿﺎﻧﺔ اﻻﻧﮭﯿﺎرات‬ BREAKDOWN MAINTENANCE M.DEP. MAJORFAULTS - FAILURE BREAKDOWN MAINTENANCE NO CORRECTION FAULTS& FAILURE
  • 10. Total Productive MaintenanceTPM is often presented as a series of pillars supporting LeanManufacturing and resting on a foundation of education andtraining. Below this is the attitude of environmental responsibilityand safety.
  • 11. Total Productive Maintenance Supporting Lean Maintenance enables and supports Lean efforts in at least three major ways: Quality, Setup Reduction (SMED) and predictability. In turn, other Lean elements support TPM through Workcells, Teamwork and Problem- Problem- solving. The Foundations Education & Training-- Education, training and investments in people characterize Training-- all aspects of Lean. In the maintenance area, they are even more important because of the specialized knowledge required on typical manufacturing equipment. This is equipment. one of the foundation stones of TPM. Without it, the pillars of TPM will have limited impact. Safety/Environment-- Underlying even the training and education piece are the Safety/Environment-- more fundamental values of responsibility to the environment and safety for employees. One important reason is simple: it is the right thing to do. A more pragmatic reason involves motivation. Most people want to be a part of something larger than themselves; appeals to higher motivation bring involvement motivation and commitment. It is difficult to argue against safety and a common commitment to common safety can be a bond that brings people together on other issues. issues.
  • 12. Zafarana  ‫ﺻﯿﺎﻧﺔ دورﯾﺔ‬TIME BASED MAINTENANCE H.R.OF TIME BASED MAINTENANCE FAULTS& MANF. PLAN NO FEED BACK FAILURE • ‫ﺻﯿﺎﻧﺔ اﻻﻧﮭﯿﺎرات‬ BREAKDOWN MAINTENANCE M.DEP. MAJORFAULTS - FAILURE BREAKDOWN MAINTENANCE NO CORRECTION FAULTS& FAILURE
  • 13. Autonomous Maintenance Autonomous maintenance is the concept that the people who operate a machine should maintain the machine. The degree of autonomous maintenance depends on the level of training and the abilities of operators. It often starts with basic lubrication, cleaning and inspection and then graduates to minor or even major repairs. For example, in the foundry where this author worked, machinists repaired and overhauled their own machine tools. A trained and competent machinist is certainly capable of overhauling a gearbox. And, as the users, they tended to know the equipment intimately. In the military, everyone cleans their own weapon. When their life depends on proper functioning, people take more care. Autonomous maintenance frees resources in the maintenance department for the other activities such as equipment improvement or major overhauls. It amplifies the maintenance efforts and involves the operators who then take better care of the equipment.
  • 14. To apply Autonomous Maintenance Reward policy. Plan for revamping people in operation not less than 3 years. Interaction between maintenance team and operation team and highlighting the problems. Information transparency
  • 15.  ‫ﺻﯿﺎﻧﺔ دورﯾﺔ‬AUTONOMUS M.+TIME BASED MAINTENANCE R.R.OF SHORT TERM PLAN T B M + A.M FAULTS& FEED BACK FAILURE P.CHECK (PRES.,TEMP.,AMP.,…VIB. CHECK)) (PRES.,TEMP.,AMP.,… • ‫ﺻﯿﺎﻧﺔ اﻟﺘﺼﺤﯿﺢ‬ CORRECTIVE MAINTENANCE MINOR FAULTS&FAULTS - FAILURE CORRECTIVE MAINTENANCE FEED BACK FAILURE P.CHECK (PRES.,TEMP.,AMP.,…VIB. CHECK)) (PRES.,TEMP.,AMP.,…
  • 16. Planned Maintenance Planned maintenance is the deliberate planning and scheduling of maintenance activities as opposed to reacting to breakdowns and emergencies. A maintenance department that uses TPM effectively generally devotes less than 10% of its labor hours to such unplanned activities. Without TPM it is not unusual for 80%-90% of the labor to be unplanned. Unplanned maintenance is a strong indicator that prevention and improvement programs are non-existent or ineffective. In addition, high percentages of unplanned maintenance creates problems. For example: Huge inefficiencies in maintenance labor. Confusion and disturbance in scheduling, production and other areas. Morale problems.
  • 17. How to plan all activities Activate Reporting Build CMMS system Activate manufacturer recommendation Predictive maintenance Check plans
  • 18. PLAN DO PLAN ACTION DO CHECK CORRECTION & MODFICATION REG. M. + OVERHAULING EG. OVERHAULING ACTION CHECK P.CHECK (PRES.,TEMP.,AMP.,…VIB. CHECK) (PRES.,TEMP.,AMP.,… CMS Aut. M CT T RE AC DI NT CODATA
  • 19. New Equipment ManagementNew equipment management is relatedsomewhat to equipment improvement. It refersto the careful design, selection and testing ofequipment. The purpose is to ensure a smoothcommissioning process with minimal designdefects and problems. New equipmentmanagement includes vendor selection,evaluating options for maintainability, trainingpersonnel in advance and other common-sensetechniques.
  • 20. Maintenance management organization
  • 21. Maintenance management organization
  • 22. Zafarana is a location with extreme conditions the wind turbines that havebeen installed have been specially prepared to cope with Egypt’s hot desertclimate, sand storms and salty air. Special seals had to be created to preventsand from getting in to the units and rotor-blade cleaning have been plannedfor several times per year.
  • 23. To utilize wind power Meteorological conditions. Location (site topography). Machine technology (turbine design). Grid connection O&M management