Danish Wind Power Academy 2016 - Vestas training / Siemens ... Presentation 2016 GB.pdf · [Module index END] Page Technical training for the wind turbine industry DWPA Presentation

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Technical training for the wind turbine industry

DWPA Presentation 2016 GB-R13

Danish Wind Power Academy 2016 Because knowledge makes all difference in your operation.…

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History Strong background. Danish Wind Power Academy (DWPA) was founded in 2004 by technicians with strong experience from the wind turbine industry. Innovative educational concept. We have developed an innovative educational concept for technical personnel at all levels. Today our instructors together count on almost 60 years of practical “hands-on” experience with the challenges from all kind of turbines, but most important…. our instructors use precisely this valuable knowledge in our training courses. High flexibility and adaptability with reference to the participants skills and backgrounds for targeted and efficient training. Wide range of training courses divided within the following fields of study: - Mechanics - Hydraulics - Electrics - WTG controller and operation.

Mission To get turbines perform as desired by technicians

achieving understanding of technology and operation.

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Target group. We focus on the technicians as their knowledge and experience are decisive for operation of the wind turbines, but today we find more than 60% of our participants on our open training classes being O&M management seeking transparency. Furthermore we have a targeted program for new employees entering the wind turbine industry with absolutely no previous WTG background Clients. Our typical clients is IPP´s, turbine owners and operators, 3rd party service providers, and not at least a large number of very important sub suppliers to the industry

DONG Energy Vattenfall E.ON Climate & Renewables RWE Juwi Wind Renewable Energy Systems EDF Renewables WindMW DUKE Energy AES Statkraft Meridian Energy AGL Energy Ltd Pacific Hydro

Target group, clients & products

Enbridge Atlantic Power Upwind Solutions Iberdrola Renewables Mitsubishi Power Systems Frontier Pro Availon B9 Energy Ltd ABB Bosch Rexroth SKF ZF Wind Power Vestas Wind Technology Ltd Siemens Wind Power A/S

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Concept

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About the DWPA training wheel. We see a training course as a dynamic process starting with the uncovering of a need for more knowledge or practical experience. If the need can be met in the best way by a customer adjusted training course, the process shown will then be passed through step by step. When the acquired knowledge and experience are anchored, you will see the favourable profit of the training course in your organisation. However, the process does not stop here. The need to develop knowledge lasts for ever and therefore the training process will be never-ending. Please visit our website at www.danishwpa.com for more detailed description of our training wheel.

2. Exchange of documentation

1. Uncovering of the need

3. Development 4. Condition Based Training

5. Reinforcement




1. Uncovering of the need.



3. Development 4. Training

5. Anchoring

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Portfolio driven utility in the US. Required performance on 450 MW must be reached Operational control of assets after EOW

Park 1 TX, 54 2,3 MW turbines, 124,2 MW TOC 2006 Park 2 TX, 55 2,3 MW turbines, 126,5 MW TOC 2008 Park 3 TX, 87 2,3 MW turbines, 200,1 MW TOC 2010

Future focus on unit performance instead of park performance KPI´s: On unit basis – Loss of production MW/h & USD

Build up in-house operational excellence Find, select and train necessary staff for operation Certification / knowledge / skills demands set for all operation personnel Target group for training: Risk, Asset, Operation, Site Management, Lead and Assistant technicians Improved operational and financial transparency




2. Exchange of documentation.



5. Reinforcement

Relevant operation data and documentation to be exchanged Today´s performance is presented by numbers and SCADA downloads of error, warning and event logs Special site conditions and specific operational challenges among main components, systems and sub systems are presented Wind turbine and possible site specific turbine documentation will be exchanged and create foundation for training First analyses of errors done and estimated ROI on training calculated First thoughts about skills and background needed from the technicians

Received Documentation OK

N/A

Comments

Installation Manual Not relevant Operation Manual x 300 pg Sparepart Catalogue x No ABB parts yet Misc. Work Instruction W/I x MK II not MK IV Maintenance Manual x Electric diagram WPS User Manual x 200-300 pg Error responce list x Timestamps not valid Electrical diagram: Turbine x 500 pg, wrong project Parameter list x

Electrical diagram: Converteam or ABB x ABB, only prototype doc






5. Reinforcement

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3. Development 4. Condition Based Training

2.1. Example of operation analysis of 25 Vestas V100 1.8, TOC 2014



DWPA Presentation 2016 GB-R13 8

2.2 Will perfect scheduled maintenance give you failure free operation? Today´s maintenance KPIs don’t reflect the true cost of the “competencies gap”

“Checklists” assume a high level of competencies possessed by the technicians, but even this is not enough to reduce downtime.




3. Development.




5. Anchoring

System

(All)

Sum of Downtime

Count of Detected

604 Remote stop 18472:17 596 7 Low voltage L2 16767:09 668 8 Low voltage L3 15781:29 661 12 Grid drop voltage L1 14245:22 710 6 Low voltage L1 4684:50 141 14 Grid drop voltage L3 2629:26 76 13 Grid drop voltage L2 1646:19 76 612 Remote utility stop 979:34 1624 252 Generator overspeed 2 961:19 211 394 Overspeed guard TAC84 956:12 206 468 Pitch ac. pressure mismatch 814:35 349 504 Main CB 1 tripped 793:40 82 205 Short untwist CCW 736:47 1480 359 Pitch oil low 696:49 178 43 Grid recovery fault 3 589:50 9 603 Safety stop 534:02 148 60 Low frequency L1 480:56 79 397 Overspeed guard TAC85 443:12 235 251 Generator overspeed 1 340:55 219 438 Hub valve supply off 333:30 72 602 Emergency stop 277:18 52 377 Yaw brake pressure too low 258:20 148 193 Gear oil temp. high long term 255:27 140 601 Manual stop keyboard 247:58 44 445 Hub computer com. fault 247:29 246 322 Pump time yaw brake too long 240:34 187 837 Press. sensor fault brake Acc. 238:38 108 1 Power up 232:51 657 841 Press. sensor fault shaft brake 225:46 127 313 Pitch main pump overload 208:14 43 226 10 min wind speed high 197:47 518 823 Thyristor L1 short circuit 184:50 4 323 Pump time pitch too long 184:21 21 63 High frequency L1 183:13 314 228 1 min wind speed high 117:55 262 302 Yaw motor 2 overload 110:48 34 305 Gear oil pump overload 110:32 35 219 Wind sensor fault 109:01 490 237 Extreme flap moment protection 107:49 1277

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We develop training courses for all people in OMS of turbines, based on their own assets and challenges. General cross knowledge of safe and correct operation of the particular turbine. Errors will be categorised in systems and subsystems with background in the root cause. Focus on selected errors in cooperation with the owner and operator




3. Development.




5. Anchoring

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Module: V82 Turbine training Training ID: 20120827DE

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No Age Name Company Job title Education field field Experience

1 DE 20-25 Servicetechniker Electrician Electrics Mechanics 0 0 2 0 50 2 DE 20-25 Servicetechniker Electrician Electrics Mechanics 0 0 1 0 50 3 DE 35-40 Servicetechniker Mechanic Mechanics Hydraulics 0 0 1 0.5 75 4 DE 25-30 Servicetechniker Mechanic Mechanics Hydraulics 2 2 5+ 0.5 75 5 DE 30-35 Servicetechniker Electrician Electrics Hydraulics 2 2 5+ 0.5 75 6 DE 30-35 Projektleiter Mechanic Mechanics Electrics 0 0.5 2 0 75 7 DE 20-25 Projektleiter Electrician Electrics Hydraulics 0 0 2 0 100 8 DE 40-45 Projektleiter Electrician Controls Electrics 3 2 2 5+ 75 9 DE 35-40 Einsatzleiter Mechanic Controls Hydraulics 3 2 4 3 50 10 DE 40-45 Servicetechniker Electrician Electrics Hydraulics 0 0,5 0,5 5+ 75

System Hydraulic Hours: min

Code Description Sum of Downtime 468 Pitch ac. pressure mismatch 814:35 359 Pitch oil low 696:49 377 Yaw brake pressure too low 258:20 322 Pump time yaw brake too long 240:34 837 Press. sensor fault brake Acc. 238:38 841 Press. sensor fault shaft brake 225:46 313 Pitch main pump overload 208:14 323 Pump time pitch too long 184:21 383 Drip tray level high 79:52 499 Unbalanced pitch - Generation 70:27 488 Pitching to run fault blade 2 64:54 459 Run pitch pressure low 41:01 486 Unbalanced pitch 40:36 150 Pitch oil temp. high 35:53 Grand Total 3200:00

0,40CP factor Feedin trarif 40 EUR/MWh

Lost turnover 21.490 18.401 6.811 6.336 6.283 5.940 5.491 4.858 2.086 1.848 1.690 1.082 1.056

950 84.322

The turbines are operated by skilled people, not by SCADA and data analysis only. The technicians skills and backgrounds are in a strong focus, with reference to the particular turbine

• In this example the technicians’ weakest skill (hydraulics) are reflected in the turbine data.

• Hydraulic errors accounted for over EUR 85K in 1 year!




4. Training.



3. Development

5. Anchoring

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Education Strongest Weakest

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Training ID

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80%

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Instructor alert field field Experience Attendance hours V82 Turbine

Electrician Electrics Mechanics 0 0 2 0 50 1 8 8 8 8 8 20120827DE 01:40 85 422 78 100 80 80

Electrician Electrics Mechanics 0 0 1 0 50 1 8 8 8 8 8 20120827DE 01:30 87 423 78 100 80 90

Mechanic Mechanics Hydraulics 0 0 1 0.5 75 1 8 8 8 8 8 20120827DE 01:35 74 424 100 67 80 (50)

Mechanic Mechanics Hydraulics 2 2 5+ 0.5 75 1 8 8 8 8 8 20120827DE 01:40 79 425 (56) 89 90 80

Electrician Electrics Hydraulics 2 2 5+ 0.5 75 1 8 8 8 8 8 20120827DE 01:40 82 426 67 100 80 80

Mechanic Mechanics Electrics 0 0.5 2 0 75 1 8 8 8 8 8 20120827DE 01:30 82 427 67 89 90 80

Electrician Electrics Hydraulics 0 0 2 0 100 1 8 8 8 8 8 20120827DE 01:40 82 428 67 100 80 80

Electrician Controls Electrics 3 2 2 5+ 75 1 8 8 8 8 8 20120827DE 01:35 85 429 78 100 80 80

Mechanic Controls Hydraulics 3 2 4 3 50 1 8 8 8 8 8 20120827DE 01:40 84 430 67 100 90 80

Electrician Electrics Hydraulics 0 0,5 0,5 5+ 75 1 8 8 8 8 8 20120827DE 01:30 85 431 78 100 80 80

With strong focus on each participant we ensure that the needed knowledge is gained. Training methods includes a strong involvement of the participants during training, supported by evening homework In 2012 we had an average certification failure rate of 13,7 %. These participants are offered a study plan and recertification within 9 month after participating in a field training plan. 96% of these participants passes the final test.

4. Condition Based Training




4. Reinforcement.



3. Development

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Mod

.

Document text Note

107 CH 547352-16903.pdf GEARBOX INSPECTION

107 AI-WI566653.pdf Dismounting top cover on Hansen gear

107 AI-WI568590.pdf Change of oil cooler

107 AI-WI573518.pdf Replacing gear supports

107 AI-WI579818.pdf Replacement of HCU

107 ZWI1001026.pdf Adjustment of gear oil pump bypass

107 ZWI1001972.pdf Packing and sealing of gear

107 ZWI1002351.pdf Change of gear oil

107 ZWI1004275.pdf Gear replacement

107 ZWI1004520.pdf Fitting of tuned absorber on Hansen gear

107 ZWI1005632_ENG.pdf Replacement of HS shaft

107 ZWI1009234_EN.pdf Replacement of HS shaft, Hansen gear

107 ZWI566637.pdf Alignment and adjustment of generator w. laser equipment

107 AI-WI566636.pdf Gear inspection

107 ZWI524866_ENG.pdf Extraction of gear oil sample

107 ZWI573989.pdf Gear assembly - Hansen gear.

107 Misc doc\Winergy Gearbox PEAB 4456.pdf

PEAB 4456 Overview

107 Misc doc\Winergy Gearbox PEAC 4300.pdf

PEAC 4430 Overview

Making sure to anchor the gained knowledge in the most efficient way. Our special tools developed for technicians, tools like checklists, inspection reports and sorted documentation linked to our training material makes sure the documentation is known by everybody, used every time and in the right way. Our “Leaning Outcome Matrix” sets up a field training plan for technicians with challenges in specific areas. On-line technical support in direct connection to reliability meetings boosts performance from day 1.

4. Condition Based Training

5. Reinforcement




1. Uncovering the need…again.




5. Anchoring

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With focus on people and unit performance the process never stops The second time we meet with our customers for new training, we find ourselves conducting specific trouble shooting training in the field, we plan gearbox exchange training or more detailed work instruction training. In 2015 we experienced that participants to 63% came from management We find O&M personnel joining our training courses even before TOC Since 2013 several training classes have been developed specially for management Stronger motivation from the complete OMS group, shared goals on KPI´s In 2016 we will present more O&M training targeted to improve our customers transparency In 2016 our spare part network supporting our customers will grow further into an international scale.




Your advantages

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Achieving a better operation The technicians will be capable of making the wind turbines

operate satisfactorily from an operating perspective, but most importantly understand “Generation Mindset”:

Downtime will be minimized Production based availability will be maximized This means efficient operation of your wind turbines, and significantly better transparency in your operation. Optimizing turbine operation Your own operational data is used to generate the most efficient training, targeted at the errors in your turbines Reduced expensive shutdowns by early fault recognition Strengthen your “knowhow” and operational excellence Optimizing the skills The targeted training optimizes your staff in proportion to your needs. Help for uncovering the future needs for resources As a result of the analysis of turbine operation data and the skills of the technicians by means of tests. Anchor your technicians. Reduce the flow of technicians thru your organization by training them to understand their job. Certification. Ensuring the needed new knowledge by the means of targeted multiple choice test.




Reference from customer in AU

91%

92%

93%

94%

95%

96%

97%

98%

99%Pct. Avalibility

At training start

6 month later

12 month later

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Facts Leading utility In-house O&M DWPA trained Wind Farm has 35 NEG-Micon NM64c-1500

Wind Farm data collected At training start 6 month after training 12 month after training





0

50

100

150

200

250

300

350Hours Scheduled Maintenance Downtime Hours

050

100150200250300350400450MWh Turbine Unplanned Outage Loss MWh

At training start

6 month later

12 month later

At training start

6 month later

12 month later

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0%5%

10%15%20%25%30%35%

6 month beforetraining in

2010

6 month aftertraining in

2010

6 month beforetraining in

2011

Pct. Capacity Factor %


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Training cost 8 technicians 4 back office operation management 5 days, NEG-Micon NM64/1500 Turbine training Total training cost EUR 28.875

Gained efficiency: Reduced scheduled maintenance downtime with 95 hours from 320 to 225 hours Unplanned outage loss reduced with 380 MW/h from 400 to 20 MW/h Availability improved with 4,28% from 94,80 % to 97,90 % ROI: Turnover increase at site EUR 20.800 per month Training cost EUR 29.000 ROI 42 days Turnover 1 year after training EUR 220.000 including training

Wind conditions: The EUR 220.000 improved turnover was further more achieved under less wind and reduced CP factor.




B39/500 B44/600 B62/1300 B54/1000 B76/2000 B82/2300

NM43/600 NM44/750 NM48/750 NM52/900 NM54/950 NM64/1500 NM72/1500 NM82/1500 NM72/1650 NM82/1650

M1500-600/150 M1800-600/150 M1500-750/175 M1800-750/175

SWT-1.3-62 CS SWT-2.3-82 CS SWT-2.3-82 VS SWT-2.3-93 SWT-2.3-101 SWT-2.3-108 SWT-3.6-107 SWT-3.6-120

V44-600 V47-660/200 V52-850 V66-1.65 V66-1.75 V80-1.8 V80-2.0 V100-2.0 V90-1.8/2.0 V82-1.65 V90-3.0 V100-2.6 V112-3.0 V105/V112/V117/V126-3.3

MWT-1000 MWT-1000A

GE SLE/XLE Bachmann-SSB

GE SLE/XLE Bachmann-GE pitch

GE 1.5 ESS GE 1.6 ESS GE 1.7 ESS GE 1.85 ESS

Training ready to improve your performance on almost 50 turbine types




Available training types Module Dura-

tion Type of training

Target group Max partic.

Leaning objectives

Performance Surveillance

3 days

Theoretical Operation, asset, risk, and contractual management

8 Strong focus on the individual turbines performance by being able to understand and evaluate operational data and the consecvenses of these in the dayli operation. Improve your operational exelence and become able to question your own or your OEM operation staff.

Turbine 5 days

Theoretical Techs, operation, asset and risk management

12 Understand all documentation, safety, complete turbine function, manual operation and all typical Achilles heels in the turbine, create foundation for trouble shooting

Maintenance 2-4 days

Practical in field

Techs, operation management

6 Understand the maintenance checklist and related work instructions, focus on “unwritten” checkpoints, refreshing manual operation IRL

Main Component & System Training

2-5 days

Theoretical & Practical

Techs, operation, asset and risk management

5-12 General or turbine specific blade, gearbox or converter training with focus on understanding impact from daily operation, damage development, how to inspect and report in a proper way, as well as how to troubleshoot and maintain the specific main component.

Advanced Trouble Shooting

2-4 days

Practical in field

Techs 6 Focus on trouble shooting related to specific systems and components, turbine training practical refreshment, how to increase unit / park performance with reference to operational condition

TOC & EOW Training

2-4 days

Practical in field

Asset and risk management, EOW inspecting techs

6 Site specific challenges and turbine conditions, with reference to installation / commissioning punch lists and available operational data, unit / park performance evaluation

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Reference list´s for our two most sold training programs Vestas V80/90/100 1.8-2.0 training Siemens SWT 2.3VS 82/93/101/108 training




Australia Belgium China Denmark Estonia Finland

Germany

Ireland

Latvia

Nederlands

Portugal Spain Sweden United Kingdom USA Poland

France

South Korea

Contact Danish Wind Power Academy Stensgaardvej 6 DK-5500 Middelfart Denmark Phone: +45 63 47 48 49 Fax: +45 64 41 61 24 E-mail: [email protected] Web: www.danishwpa.com CEO: Carsten Lind Andersen Phone: +45 63 47 48 40 Cell: +45 40 19 48 43 E-mail: [email protected]

Brazil Costa Rica

We conduct cost efficient and condition based training for the wind turbine industry precisely where its needed!

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New Zealand

South Africa Turkey

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Danish Wind Power Academy 2016 - Vestas training / Siemens ... Presentation 2016 GB.pdf · [Module index END] Page Technical training for the wind turbine industry DWPA Presentation