Capacity building 2010 day 1 maintenance activity

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

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Capacity building 2010 day 1 maintenance activity

  1. 1. Ministry of Electricity & Energy (MEE)New & Renewable Energy Authority (NREA) Zafarana Wind Farm
  2. 2. Ministry of Electricity & Energy (MEE)New & Renewable Energy Authority (NREA) Zafarana Wind Farm Contents:- 1- Zafarana location and layout. 2- Zafarana projects and Statistics. 3- Maintenance concepts. 4- Availability. 5- Maintenance types (Preventive, Corrective and Predictive). 6- Cleaning blades.
  3. 3. ZAFARAN CairoZafarana site locationIn the south east of Cairo by190 km
  4. 4. Site layout for Zafarana wind farms Gulf of Suez Unused Area Spain 85 MW Japan Total Area = 120 Km2 120 MW German Substation 80 MW 47 MW Zafarana 33 MW offices Danish 120 MW 30 MW 30 MW
  5. 5. Zafarana Wind FarmZafarana - 1 : 30 MW50 WTG 600 Kw Nordex (N43) TurbinesZafarana - 2 : 33 MW55 WTG 600 Kw Nordex (N43) Turbines. Nordex = 105 WTG 63 MWZafarana - 3 : 30 MW46 WTG 660 Kw Vestas (V47) TurbineZafarana - 4 : 47 MW71 WTG 660 Kw Vestas (V47) Turbines Vestas = 117 WTG 77 MW
  6. 6. Zafarana Wind FarmZafarana – 5 : 85 MW100WTG 850 Kw Gamesa G52 TurbinesZafarana – 6 : 80 MW94 WTG 850 Kw Gamesa G52 TurbinesZafarana – 7 : 120 MW142WTG 850 Kw Gamesa G52 TurbinesZafarana – 8 : 120 MW142WTG 850 Kw Gamesa G52 Turbines Gamesa = 478 WTG 405 MW
  7. 7. Zafarana Wind FarmNordex turbines 10 years of operation started at end of 2000 Vestas turbines 7 years of operation started at beginning of 2003Gamesa turbines 4 years of operation started at end of 2006
  8. 8. Zafarana Wind Farm Total Number of Turbines :- 700 WTG Total Power Capacity:- 545 MW Statistics from 1/7/2008 till 30/6/2009 SubstationTotal energy produced:- 944,222.00 MWhTotal fuel saving:- 204.9 K ton of fuelEmissions reduction:- 519,3 K ton of co2
  9. 9. Zafarana Wind Farm The Concept of MaintenanceMain objective of maintenance is to run the machinesafely and minimize damages & breakdown times inorder to achieve maximum benefit from the operationof the machine. Good Good MuchMaintenance = availability = power
  10. 10. Maintenance & ToleranceMaintenance Degree of overtaking (Tolerance) Daily None Weekly ± 1 Day Monthly ± 3 Day Quarter year ± 1 Week Half year ± 2 Weeks Yearly ± One month
  11. 11. Maintenance Obstacles1- Shortage of spar parts. (Inventory control)2- Shortage of proper Tools. (Special tools & devices)3- Shortage of skilled persons. (Training facilities)4- Shortage of information. (Catalogs & Instructions sheet)
  12. 12. Availability %Availability is an indicator measuring the efficiency of maintenance (A) A % = MTTF /( MTTF + MDT ) MTTF : Mean Time To Failure ( Reliability ) MDT : Mean Down Time (Breakdowns time)
  13. 13. MDT = MWT + MTTRMWT : Mean Waiting TimeMTTR : Mean Time To Repair Availability %MWT : Mean Waiting TimeMTTR : Mean Time To Repair
  14. 14. Availability statistics for Zafarana wind farm Nordex Vestas Gamesa Real data from Zafarana Control Room
  15. 15. Availability 2007100% 99%99% 98%98% 97% 97% 97% 97% 97%97% 96%96% 95% 95% 95%95%94% 93%93%92%91%90% Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
  16. 16. Availability 2008100% 98%98% 97% 97% 97% 97% 97% 97% 96% 96%96%94% 93% 92%92% 90%90%88%86% Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
  17. 17. Availability 2009100% 0.96 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.9595%90% 0.8585%80%75% Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
  18. 18. Maintenance Activity 1- Corrective Maintenance (Remedy of unexpected breakdowns)2- Preventive maintenance (Periodical Maintenance )3- Predictive Maintenance (Early detection of failure & planning for repair)
  19. 19. Life Cycle Coast & Maintenance types L.E Corrective MaintenanceCoasts Preventive Maintenance Predictive Maintenance Life time Machine Machine Machine Years Failure 1 Failure 2 Failure 3
  20. 20. General precautions1- Your safety is the first priority.2- At least 2 person doing the activity of Maintenance.3- Wearing safety equipment is very important ( safety belt, safety shoes and Helmut).4- All tools needed should be prepared ( Hi torque machine, grease guns, torque wrenches, screwdrivers…….etc).5- All devices needed should be prepared ( Service box, fluke, nitrogen charger, clampamps.,……..etc).6- All lubricants needed should be prepared ( gear oil, hyd. Oil and greases).7- All cleaning equipment should be prepared ( clothes, cleaning liquids).8- All tasks should be done according to recommendations of the manufacturer (Maintenance sheet)
  21. 21. Preventive maintenance (Periodical Maintenance) Routine Maintenance NORDEX MAINTENANCE TYPES TYPE 3 TYPE 4 TYPE 2 AFTER FIREST 0NCE EVERY AFTER FIREST 12 MONTHES AND, FIVE YEARS 6 MONTHES AND, THEN ANNUALLY LUBRICATION THEN ANNUALLY LUBRICATION INSPECTION LUBRICATION INSPECTION CLEANING INSPECTION CLEANING RETORQUE CLEANING RETORQUE REPLACING……
  22. 22. Preventive maintenance (Periodical Maintenance ) Routine Maintenance VESTAS MAINTENANCE TYPESCleaning blades TYPE 3 TYPE 1 TYPE 2 0NCE EVERY AFTER FIREST ONCE EVERY YEARS 3 MONTHES 6 MONTHES LUBRICATION LUBRICATION LUBRICATION INSPECTION INSPECTION INSPECTION CLEANING CLEANING CLEANING MEASURMENTS RETORQUE RETORQUE
  23. 23. Preventive maintenance (Periodical Maintenance ) Routine Maintenance Gamesa MAINTENANCE TYPES TYPE 3 TYPE 1 TYPE 2 0NCE EVERY AFTER FIREST ONCE EVERY YEARS 3 MONTHES 6 MONTHES LUBRICATION LUBRICATION LUBRICATION INSPECTION INSPECTION INSPECTION CLEANING CLEANING CLEANING MEASURMENTS RETORQUE RETORQUE
  24. 24. Very Important note:- Do not forget to LOCK THE ROTOR before doing any (measuring, re-torque lubricating and cleaning …etc) Inside the Hub.
  25. 25. Inspection During Maintenance Look & observe Ask For ForLeakage & cracks Repair Major faults Listen Feel For For Strange sound Check & Determine Unusual & Noise For Wear & damages General Note:- The Most important task on turbine is Cleaning
  26. 26. Mechanical Tools used on service
  27. 27. Mechanical Tools used on service Hi-torque Machine Hi-torque Device For VESTAS Turbine For NORDEX Turbine
  28. 28. Electrical Devices used on service & trouble shooting Fluke Clamp Amp. Transformer. Ratio meter Megger
  29. 29. Corrective Maintenance (remedy of unexpected breakdowns) Faults Major Minor1- Changing Gearboxes, Main bearings, Daily repair & changeCardan shafts, break discs, Power cables and 1- Contactors, relays, fuses &Generators for Nordex turbines. electrical motors. 2- Electronic cards, CT modules,2- Changing Gearboxes, Composite shafts, sensors & softwarespitch cylinders, Power cables, Generators &ground controller cabinets for Vestas 3- Hydraulic pumps, valves, oilturbines. seals & hoses
  30. 30. Changing pitch cylinder for Vestas
  31. 31. Changing gearbox for Nordex
  32. 32. Changing Generator for Vestas
  33. 33. Changing Gearbox for Vestas
  34. 34. Cleaning Heat exchanger for Nordex Liquid InLiquid out Heat exchanger Tank Pump with elec. motor
  35. 35. * Chemical liquid or Gasoline are used for cleaning Heat exchanger * The efficiency of Heat exchanger isincreased up to 85%
  36. 36. Corrective Maintenance (local repair for defective parts)1- Rehabilitation of gearboxes (changing bearings) at Z workshop2- Rehabilitation of generators (changing bearings) at Z workshop3- Rehabilitation of generators (rewinding) at ABB & Gamma Co. For Nordex turbines4- Rehabilitation of generators (rewinding) at ABB & Gamma Co. For Vestas turbines5- Repairing small elec. motors (rewinding + change bearing) at Z workshop.6- Repairing Electronic cards for (WP 3000, WP 2035) & wind sensor s.
  37. 37. Changing Bearings for Nordex Gearbox Turning Gearbox other side for dismounting High speed shaft Gearbox is readyReinstalling bearings andbearings Gearbox Parts Planetary mounting Bearings for intermediate
  38. 38. Changing Bearings for Vestas Generator
  39. 39. Repairing small elec. motors for Nordex & Vestas
  40. 40. Changing Bearings for Nordex Anemometer
  41. 41. Predictive Maintenance (Early detection of failure & planning for repair)All modern turbines are equipped with a lot of sensors for monit oringdifferent functions. ( Temperature sensors, filter choked sensor s andvibration sensors.Oil analysis for gearboxes to estimate oil & gearboxes condition.Vibration measurements for estimating unbalance & bearings condition.End scope measurements for estimating gearbox teeth & bearings condition.Visual inspection for blades for estimating its condition.Measuring with dial gauge can help for detecting wear and excess clearance
  42. 42. Temp. Sensors Wind Van Top box AnemometerMonitoring bearing temp. bearing temp. Monitoring H.S.shaft for Main shaft Monitoring oil temp for Gearbox Monitoring Bearing temp. for Generator Monitoring windingAmbient temp. Monitoring temp. for Generator
  43. 43. Vibration device
  44. 44. Dial Gauge
  45. 45. Finally For achieving Excellent Maintenance, Trouble shooting& repair 1- Skilled staff should be exist (Eng. & Tech.) Training is necessary 2- Suitable tools for different tasks should be exist. Special tools is very important3- Spare parts (Major – Minor) available when needed. Enough stock at store house
  46. 46. ThanksBest Wishes for All

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