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GE Energy

GE Energy. Effective Operation and Maintenance of Wind Turbines Through Use of Advanced Services Technologies. Philippe Kavafyan GE Energy February 2006 Athens, Greece. Decreased. Availability. Cost. -. of. -. Energy. Decreased. Production. O&M Costs. Decreased.

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GE Energy

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  1. GE Energy Effective Operation and Maintenance of Wind Turbines Through Use of Advanced Services Technologies Philippe KavafyanGE EnergyFebruary 2006Athens, Greece

  2. Decreased Availability Cost - of - Energy Decreased Production O&M Costs Decreased A Significant Portion of COE Revenue Large Variance 3-5% Wind Project IRR is allocated to risks associated with variances in energy production and cost of O&M Cost Variance Unplanned ~70% • Service Access O&M WTG, • Crane Cost BOP & Other • Material Cost • Labor Cost Planned ~30% • • … A Comprehensive O&M Strategy is Critical to Successful Project Economics

  3. O&M Cost Variability Driven By Product Reliability • Life-cycle Reliability Has Large Impact on O&M Costs • Planned O&M can vary from 10% to 35% of total cost • Offshore Access … jack up barge, weather, etc. add additional cost and variance Offshore Access Unplanned O&M Planned O&M Total O&M Cost 1 4X 10X Wind Turbine Reliability … Unplanned O&M Cost Significantly Impacted by Component Reliability

  4. Production Impact from Unplanned Events Event 1: Remote Resolution Event 2: Requires WTG visit & small Max Wave Height - by Month component replacement Event 3: Requires WTG visit, major 4 component replacement w/ 3 jack up barge Wave Height (m) 2 1 0 JUN DEC JAN FEB SEP JUL AUG NOV APR OCT MAR MAY Annual Energy Production 14000 13500 13000 12500 12000 MW-Hrs 11500 11000 10500 10000 1 2 3 Event Event 2 Event 3 Event 1 Access Threshold Unplanned Downtime Wind Turbine Availability 100 95 90 85 Availability (%) 80 75 70 1 2 3 Event … Accessibility Key to Managing Impact of Unplanned Events

  5. Realistic Realistic Reduce risks to revenue & costs from turbine failures Loss Revenue due to Increased Wear & Tear and Failure Rates, which results into reduced Availability Revenue Revenue Customer View Profit $ Additional Costs after Warranty Expires O&M Costs Customer View Customer View 2 0 0 20 Year Year Current

  6. How is GE addressingthis challenge?

  7. Apply Services Best Practices • GE Services • > 30,000 Major Equipment Under Service Worldwide • > 100 Services-related patents • Creating New Services Technologies For ~ 20 Years • Contract Performance • Parts Life Management • Asset Management SmartServices Increasing Customer Value • Performance & Availability Guarantees • Equipment Upgrades • Plant Energy Management PerformanceOptimizationServices • Equipment Support • Anomaly Detection • Condition Assessment • Diagnostics & Troubleshooting • Repairs & Upgrades Equipment Services & Products 6s IndustrialEquipment Power Plant Medical Equipment Aircraft Engines Locomotives

  8. Service Technologies for Effective O&M Product Reliability (Prevention) Field Services • Enhanced Offshore Equipment Designs • Advanced Controls for Load Mgmt & Performance • Design for Serviceability • High Quality Planned & UnplannedMaintenance • O&M Asset Management • EHS Trained Product / Customer Support Continuous Improvement • 24/7 Remote Operations, Monitoringand Diagnostics • Predictive & Condition Based Maintenance • Contractual Services/Warranty Mgmt • Reliability & PerformanceModifications & Upgrades Customer Benefits Revenue  COE  Reliability  Availability  Production  … Multi Pronged Service Approach Required

  9. Product Reliability (Prevention) Physics-based Models Extended FMEAs Advanced Controls Serviceability • Goal: Design turbines to deliver very high availability …. Breaks Down Rarely • Approach: • Utilize “Design for Reliability” & Serviceability • Extended FMEA analysis to define causal events and impacts of failures • Physics-based Reliability Models to understand true design and operational limits • Redundancy of selected components to reduce availability impact of failures • Advanced Controls for Load Management & Performance enhancement

  10. Product / Customer Support Automated Fault Notification • Approach: Customer Support Centers • 24/7 Remote Operations, Monitoring and Diagnostics • Automated Fault Notification • Expertise-based Fault Resolution • Remote Communication Reliability Support Centers Major Faults Detailed Diagnostics Major Faults Major Faults Detailed Diagnosis Detailed Diagnosis Error 180: Error 180: „Wind deviation“ „Wind deviation“ Germany Wind Wind Wind Remote Control Remote Control Remote Control Remote Control NO NO YES YES Is there any of the Is there any of the Are the parameters Are the parameters Timeout pitch Timeout pitch Timeout pitch non non - - resetable errors resetable errors 7.5 and 7.6 at the 7.5 and 7.6 at the California in the turbine status? in the turbine status? correct values? correct values? Deviation Deviation Deviation controller controller controller NO NO Rest Rest Rest Remote Control Remote Control Remote Contro Remote Contro l l Is the PLC software Is the PLC software Change the Change the Atlanta HQ Pitch Overrun Pitch Overrun Pitch Overrun version recent? version recent? parameters parameters YES YES 90° 90° 90° Shanghai Next 21 Next 21 Next 21 YES YES NO NO NO NO Faults Handling Faults Handling Faults Faults Faults Service Team Service Team Remote Control Remote Control Go on the site and change the Go on the site and change the Is t Is t he status OK he status OK PLC software. PLC software. Collective Collective Collective Procedures Procedures in the in the wtg wtg status status ? ? fault pitch fault pitch fault pitch Undervoltage Undervoltage Undervoltage Remote Control Remote Control Need further investigation Need further investigation depending on the following depending on the following errors errors controller controller controller NO NO YES YES 3 pitch 3 pitch 3 pitch controller controller controller Remote Control Remote Control Remote Control Remote Control Blade pitch Blade pitch Blade pitch Further investigation is Further investigation is Log the alarm in the Log the alarm in the needed needed ( ( snapshot snapshot ) ) . There . There Access datab Access datab ase ase might be following errors might be following errors faults faults faults control dev. control dev. control dev. in the in the turbine turbine status status . . END END • Goal: Increase Availability….Minimize Field Costs…. Increase Customer Value

  11. Reliability-Based Preventive Maintenance Strategy Goal: Reduce Unplanned Maintenance … Increase Production • Approach: Efficient Risk Allocation • Contractual Services/Warranty Mgmt • Predictive & Condition Based Maintenance • Shift Planned Maintenance to Low Wind Period • Use Reliability Models to Drive Maintenance Intervals for Optimal Performance • Use Site-specific Maintenance Factors to Assess Damage Accumulation

  12. rotor side bearing total loss of gearbox Approach: Gearbox Metallic Particle Monitoring planetary bearing inspection roller roller rotor side bearing rotor side bearing Total Cumulated Number of Metallic Particles > 200 Microns in Gearbox Oil measurement forecast 11. Jun 04 outer ring 11. Jun 04 middle baring middle bearing June ‘04 Oct ‘04 2006 2005 Aug ‘05 Condition Based Maintenance Goal: Increase Damage Predictability

  13. Offshore Field Services • Goal: Effective Access System & Logistics for rapid field response • Offshore Access Systems • Commissioning • Regular O&M duties • Overhaul tasks • Access/Weather Modeling • Jack-up Barge Logistics • Service Friendly Equipment • Asset Management Project % Wave Height > 2.0 Meters Project 1 48% Project 2 3.5% Project 3 8.1%

  14. Product Continuous Improvement z y x Power &Performance Uprate Adaptive Drive Train Damper Control Upgrade • Goal: Increase Reliability & Production Capability Through Modifications and Upgrades • Approach: • Identify Opportunities • Fleet Reliability and Availability Metrics • Fleet Faults & Root Cause Analysis • Residual Life Prediction Tools • Introduce Modifications and Upgrades from RCA & New Technology Development

  15. Why Services Agreement with OEM? • More efficient risk allocation between the Owner and OEM (Original Equipment Manufacturer) • Owner Keeps Commercial Risk (Wind Risk, Energy Pricing) • OEM takes on Equipment & Performance Related Risks • OEM is in the best position to manage this risk in a cost effective manner • Design and Manufacturing expertise • Built-in incentives to maximize return on investment for the owner – a partnership arrangement • Benefits from new products & technology development

  16. Summary • Effective O&M is Critical for Reducing Project Risks • Unplanned Maintenance Drives Variationin Cost & Loss in Production • GE focused on developing ServicesTechnology … key to cost effectivelymanaging O&M

  17. GE Energy "Effective Operation and Maintenance of Wind TurbinesThrough Use of Advanced Services Technologies" Philippe KavafyanGE EnergyFebruary 2006Athens, Greece

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