Jason Watson Acciona Energy
Jason Watson
Acciona Energy
Implementing Maximo in the Wind Industry
The wind industry is a rapidly growing industry in Australia and aroundthe world.
The proper management of the wind turbines and associatedinfrastructure is important in maximizing the performance and returnon these assets.
MXES is being implemented globally by Acciona Energy as theprincipal tool for asset management.
Acciona
Acciona Group is a leading corporation in the development, promotion andmanagement of infrastructures and services oriented towards sustainabledevelopment and social welfare
Acciona Group comprises:
• Infrastructure
• Real Estate
• Energy
• Water
• Logistics and Transport
• Urban & Environmental Services
Acciona Energy
Acciona Energy is a global leader in renewable energy
Horizontal integration of activities
B. Major projects in renewables (30.06.2006)
Biomass: 33 MW -30% of the primary biomass in Spain-
Wind: 3,876 MW installed -6% of the world total- (2,636 MW part., 2,008 attr.)
Solar: 18,8 MW PV (35% of the Spanish market) and 19 MW thermal installed
Small hydro: 59 MW –3.6% in Spain-
Biofuels: 35,000 tonnes per year biodiesel plant (1.2 Mtonnes in project)
ACCIONA also has 115 MW in cogeneration
Acciona Energy, Leader in wind
A. Wind power / leadership in several activities
First developer
and constructor
of windparks
in the world
Eighth world
manufacturer
of wind turbines
Fourth world
operator
of windparks
Third largest owner of
wind energy assets in the
world, and second in Spain
Acciona Energy is:
Implementing Maximo in the Wind Industry
B. Present in the entire wind energy value chain
Wind turbine design
Wind turbine manufacture
Development
Financing
Turnkey
Property Local partners
O&M Local and remotecontrol24h x 365 days
Marketing of energy and CO2
Under development
Selection of sites, environmental impact,relations with local authorities
Construction, admin.processes and project management
Financial analysis,structuring and due diligence
Vertical integration
In-house technology
Implementing Maximo in the Wind Industry
Attributable Power (MW) Country Total Power (MW)Number of Installations
TOTAL
Spain
Germany
France
USA
Canada
Australia
Italy
Greece
Hungary
2,951
116
94
86
60
66
33
35
24
2,315
116
47
12
20
33
17
35
11
C. Wind power capacity owned by Acciona Energy by country (30.06.07)
101
10
14
2
2
1
3
1
1
3,465 2,606135
Maximo in Acciona Energy
Maximo 6.2 is being implemented by Acciona Energy across its globaloperations.
Project based in Spain and Australia.
Spain – focused on the implementation of maintenance of windturbines
Australia – focused on the commercial and financial aspects
Consolidation of system into a global system
Maximo in Acciona Energy
Drivers for the implementation of Maximo
Technical• Technically complex machines, requiring ongoing preventative,
predictive and corrective maintenance
Commercial• Significant investment, where return is based on the production of
the turbines
Stakeholder• Numerous stakeholders with diverse expectations from the turbines
Implementing Maximo in the Wind Industry
Challenges within the wind industry
• Rapidly growing industry – averaging 30% per annum
• Rapidly developing technology – 100 x increase in power output in25 years
• Complexity of machines increasing
• Attitude to wind power
Technical – Wind Turbine
Technical chracteristics (I)
• Variable speed
• Rated power: 1,500 kW
• Rated voltage: 12 kV
• Generation frequencies: 50 / 60 Hz.
• Generator: double-fed asynchronous
• Rotor diameters: 70 and 77 m.
• Hub height: 60 and 80 m.
• Three bladed wind turbine oriented windward
• Horizontal shaft
AW-1500 turbine in the Vedadillo windpark (Navarre)
4. AW-1500 wind turbine
Technical – Wind Turbine
Technical – Wind Turbine
Generator
High speed shaft
Gearbox
Doubleframe
Main shaftHub
Essential components
2 BearingsSupport
Independentpitch controlfor eachblade
Technical – Wind Turbine
Asset Management on the Turbines has several key points
A large number of parts replaceable and serial number tracked
Complex structure of parts and components
Differing expected lifetime of major components• Gearbox 10 years• Blades 25 years• Generator 25 years• Tower 50+ years
Use of Maximo to track the life of components
Turbine Performance
Turbines are highly automated
• Detect and respond to wind conditions
• Detect and respond to grid conditions
• Detect and respond to plant condition
Turbine Performance
Turbines are highly efficient
Achieving at least 90% availability
Conversion of 50% wind energy into electricity
Wind farms designed to achieved 30-40% capacity factor – actualoutput versus theoretical maximum output
Accurate forecasting 24-48 hours in advance
Implementing Maximo in the Wind Industry
Additional infrastructure on a Wind Farm
• High voltage substations
• High voltage cables and overhead lines
• Communication and SCADA system
• Roads, gates, culverts and civil infrastructure
• Meteorological monitoring stations
• Facility buildings
• Vehicles and tools
TechnicalHow does Maximo fit in?
• Provide an accurate record of installed equipment
• Provide an accurate history of turbines and plant
• Schedule predictive and preventative maintenance
• Track corrective maintenance
• Provide information for engineering analysis
• Link to information sources (commissioning records etc)
Installed equipment
Utilise the Location / Asset / Item structure to mirror turbine
• Tracking of serial numbers
• Number and location of components – optimization of spares
inventory
• Specification templates – technical specifications
• Item assembly structures - management of the structure
• Alternate items
Installed equipment
Interaction with the inventory and purchasing system
• Correct identification of parts from structure
• Consolidation of demand to stores and warehouse
• Optimisation of purchasing
Waubra Wind Farm
Site (approximately 173km²) is a series of hills and high plateaus whichform part of the Great Dividing Range, approx 20km from Ballarat
Site consists primarily of cleared agricultural land used for sheep andcattle grazing and potato growing
128 x 1.5 MW wind turbines, with associated access tracks, substationsand an operations centre
A total installed capacity of 192MW
Green energy for 143,000 households – more than enough to powerthe City of Ballarat
Waubra Wind Farm
Maintaining Wind Turbines
Maintenance requirements of Turbines
• 24/7 operation
• Service every 6 months 6 monthly 12 monthly 24 monthly
• Gearbox refurbishment every 10 years
• Average personnel requirement of 1 technician for every 6 turbines
Maintaining Wind Turbines
Work Orders
Incorporates permit requirements for:• High Voltage• Working at heights• Confined space
Panned and Actual Permits – from Job Plans
Commercial Reality
The profitability of a windfarm operation is dependant on:
• Maximising the output from the available wind
• Minimising the cost of operation
Maximising Production
There are two key measures of turbine performance
AvailabilityUtilisation
Availability is the measure of when the turbine is running, or capable ofrunning
Utilisation is the measure of actual power output vs theoretical poweroutput
Both are adversely affected by stoppages due to alarms, defects andscheduled stops for maintenance.
Maximising Production -Minimising stoppages
Alarms
24/7 hour control room for the immediate reaction to alarms60% of alarms can be reset remotely
24/7 on-call techniciansResponse time a key performance indicator
Engineering analysis of alarms to identify root cause• All stoppages raised as work orders in Maximo• Response to alarm recorded and measured• Failure Codes in Maximo utilised to assist in engineering analysis• Global consolidation of turbine data to provide large dataset for engineering
analysis
Maximising Production -Minimising stoppages
Defects
Identification of all defects as work orders in Maximo
Priority system to address defect1. Immediate attention2. As soon as practicable, within 2 weeks3. At next scheduled service4. Ongoing observation
Priority system for equipment as well1. Major electrical and communication infrastructure2. Minor electrical and communication infrastructure3. Turbine4. Civil infrastructure
Maximising Production -Minimising stoppages
Scheduled stops
Scheduled stoppages are used for preventative and predictivemaintenance
Duration of stoppage minimisedEfficient work practicesEffective inventory controlClear and precise work instructionsMultiple work shifts
Planning based on forecast wind speed to improve utilisation requiresgreater flexibility and accurate knowledge of planned work
Minimising Cost
Once constructed, maintenance is the major ongoing cost in theoperation of the wind farm
Minimistion of cost is achieved through the balancing the maintenancerequirements to appropriate levels of resources
Efficient work practicesOptimisation of inventoryBalancing the resources with the maintenance requirements
Effective use of Maximo improves the management of these areas.
Stakeholders
There are a large number of stakeholders within an operating wind farm
Commercial partners Joint venture partners
Electricity industry Grid connection utilities NEMCO Energy Retailers
Community Landowners Local community Public
Stakeholders - Commercial Partners
Acciona Energy wind farms in Australia are joint ventures.
Complex legal and financial aspectsSeparate chart of accounts for each legal entity
PWED
AEO
AWP Contractors
PWED
AEO
AWP
Contractors
AEO
PWED
AEO
Contractors
Construction Warranty Operation
Stakeholders – Electricity Industry
Wind farms connect into the National Grid
Wind farm must;• Operate stably and securely in National Grid• Meet the power generation obligations to the energy retailers• Coordinate maintenance and operations with other generators and
utilities within the gird
This requires reliable turbine operation and accurate planning
Stakeholders – Community
Wind farms have an impact on the surrounding community.Large public interest in the wind industry.Wind farms must be responsible corporate citizens.
Maximo assists the wind farm in providing
• Accurate information for reporting and communication withinterested parties
• Management of the contractual obligations of the wind farm withland owners
• The ability to record and react to changing local conditions
Stakeholders – Land owners
Management of land owner requirements essential to the construction andoperation of the windfarm.
Record of land title and installed assets
Lease payments for access to land
Management of local conditions Land usage (cropping etc) Correction of defects
Communication with land owners Upcoming work plan Performance of turbines within their property
Stakeholders – Land owners
Lease payments
Land owner lease payments based on: Access for the planning and development of windfarm Lease of land for the installation of meteorological monitoring
stations Access for the construction of the windfarm Lease of land for the installation of turbines and substations
Stakeholders – Land owners
Lease payments
The management of the lease is very important Key dates to meet Payments are linked to CPI Land titles change hands Long term contracts
Waubra has 36 directly effected land owners with93 land titles
Stakeholders – Land ownersLease payments
Customised lease application• Location structure for land titles• Leased assets for land access rights, met masts, turbine
foundations• CPI increase calculated using currency exchange functionality
Stakeholders – Community and PublicCommunity Reference Group as a link between community and the
wind farm
Accurate information and follow up on raised issues
Implementing Maximo in the Wind IndustryGlobal Consolidation
Master Maximo system willreside in Spain
Local systems in Spain, UnitedStates and Australia
Consistent design and structureInformation merged via the MEAapplication into consolidateddatabase
Consolidated MaximoSpain
Spain United States Australia
Implementing Maximo in the Wind Industry
Summary
The emerging wind industry is dependant on accurate and effectiveasset management.
Maximo provides a range of tools applicable to the management of thedevelopment construction and operation of the wind farm
Cope with the complexity of a wind farm Provides existing tools that can be leveraged to meet the wind
farm requirements Simplify the requirements for the people working within the
rapidly growing industry
Implementing Maximo in the Wind Industry
Thank you
www.waubrawindfarm.com.auwww.waubrawindfarm.com.au
www.acciona-energia.comwww.acciona-energia.com