OPERATION AND MAINTENANCE
Levent İshak
Service Manager, Vestas Turkey
IWPC 2015-Istanbul- April 2015
If your new car
drove as much
as a wind
turbine,
it would have to
be scrapped
after
6 months*.
‘) The average car is scrapped after 4500
hours of operation. This equals 6 months
Operation of a wind turbine (www.dkwind.dk).
A Challenging Environment
Wind Industry’s
Service and Operational Risks
 Turbine performance during optimum
conditions
 Performance management expertise
 Budgeting for unplanned maintenance
events
 Spare parts access & availability and
supply chain reliability
 Shortages in skilled workforce
 Safe and environmentally friendly
footprint for O&M
IWPC 2015-Istanbul- April 2015
Customer’s Cost of Energy
Reliability Curve
Failure rate
Early life failures
Stable reliability
Increased failures
PartCustomer
C Part Risk
B Part A
Vestas warranty
Vestas offering
Vestas
Service Offerings
Decreased
Weibull
Weibull Weibull
Technical Support
Improved reliability/productivity
Weibull out
Vestas Service
Knowledge management
Reduced EOL part cost
d
Value:
Re-engineering/part reliability
o
w
Productivity &
Predictive Diagnostics
n
Lower Cost
Highly skilled & trained local
Customer
service
Risk
Years
IWPC 2015-Istanbul- April 2015
Vestas Active Output Management® (AOM) Service
Philosophy
Our commitment to helping you achieve maximum ROI.
Superior service and certainty through:
the RIGHT PEOPLE, supported by
the RIGHT INTELLIGENCE, using
the RIGHT OPERATIONS AND MAINTENANCE PLAN, executed with
the RIGHT INFRASTRUCTURE, maintaining
a strong PARTNERSHIP with our customers
… backed by performance guarantees
5
IWPC–2015-Istanbul2015
AOM
Active Output April
Management®
40
GW
currently
serviced
under an
AOM Contract
5500
The Right PEOPLE
Advanced turbine technology and safe operations require competent personnel.
VESTAS TECHNICIANS arrive well prepared, supported by a large team &
knowledge base. You benefit from:
CERTIFIED TRAINING
SAFETY VALUES
employed
worldwide to
ensure
superior
turbine
operation
FIELD EXPERIENCE
Training certified by:
 Certified technicians
(4 levels) with the right
knowledge and skills
 Industry leader in safety
and training
 Mandatory “Safety
Walks” by management
 Highest HSE standards,
OHSAS 18001 certified
 Technicians empowered
to stop work if something
appears unsafe or
someone is at risk
 R&D optimised
diagnostics and
maintenance strategy
 “Safety First” is the
primary value driver for
Vestas service
technicians
6
IWPC–2015-Istanbul2015
AOM
Active Output April
Management®
 Support from technical
help desk
 LEAN problem solving
techniques
The Right INTELLIGENCE
Vestas builds predictive intelligence through research, monitoring and field
experience to maximise the output using different systems.
VESTAS PERFORMANCE AND DIAGNOSTICS CENTRE (VDPC) monitors
over 21 000 turbines amounting to almost 40 GW
DATA
ANALYSES
 Assessing the "health"
of a machine by
analysing measured
signals
 Assessments
integrated into work
planning
7
IWPC–2015-Istanbul2015
AOM
Active Output April
Management®
VTM – Vestas Turbine Monitoring
CMS – Condition Monitoring System
 Analysing more than 130
signals from heat sensors
 Detecting potential failures
and outliers
1/6
of the world’s
installed
wind capacity
is monitored
by Vestas
PREDICTIVE
CONDITION BASED MAINTENANCE
 Estimating the time of failure
 optimised planning of
maintenance activities
 In-house ISO Certified
Vibration Engineers
 Assessments integrated into
work planning
The Right OPERATIONS and MAINTENANCE PLAN
Maintenance operations and planning are executed synchronously by prevention
through prediction.
Vestas Turbine Watch provides 14+ years
expertise in of 24/7/365 SURVEILLANCE
14 +
years of
expertise in
24/7/365
surveillance
Performance deviations in the fleet are
identified to INITIATE OPERATIONS
activities at the RIGHT TIME
MONITOR
IDENTIFY
&
INITIATE
Maintenance strategy
Preventive
Maintenance
Predictive
Maintenance
LEARN &
IMPROVE
Corrective
Maintenance
Findings used to
provide RELIABLE PERFORMANCE &
OUTPUT MANAGEMENT
8
IWPC–2015-Istanbul2015
AOM
Active Output April
Management®
PLAN &
REPAIR
Planning of maintenance based on
Vestas weather forecast
to MAXIMIZE PRODUCTION
The Right INFRASTRUCTURE
Synchronized service support structure.
24/72
hours delivery
time worldwide
of
spare parts /
main components
GLOBAL SPARE PARTS AND REPAIR
► Global delivery, logistics and sourcing network, local warehouses
► Certainty of quality, supply and control of cost
► Repair capabilities for generators, gearbox and other components
TECHNOLOGY HOTLINE AND PRODUCT UPGRADES
1st Level Support
► 24/7 surveillance center/hotline accessible through email or phone
2nd Level
Support
► High expert knowledge available at country or region level
► Open normal business hours, accessible through 1st level support
Technology R&D
► Access to unique OEM technical expert knowledge
► Failure analysis & proactive engineering upgrades to enhance
performance
CUSTOMISED ERP AND PROPRIETARY FAQ
► ERP Work Order and Guides for fixing issues, list of necessary spare parts and list of
other maintenance tasks
► Efficient service operations and strategic maintenance planning
9
IWPC–2015-Istanbul2015
AOM
Active Output April
Management®
thethe
RIGHT
RIGHT
the RIGHT
PARTNERSHIP
EQUIPMENT
PEOPLE
8
The Right PARTNERSHIP
Maximizing the partnership through ongoing communication.
Vestas
Training
Centers
worldwide
CUSTOMER PORTAL
VESTAS CUSTOMER PORTAL contains
documentation, news, alerts and monthly progress
reports for all customer projects in one place
BUSINESS REVIEWS
BUSINESS REVIEWS at the customer account level to
discuss performance and technical issues
CERTIFIED TRAINING
Certified CUSTOMER TRAINING on safety and
operation to empower customers to manage their
assets
10 AOM
IWPC–2015-Istanbul2015
Active Output April
Management®
IS THIS ENOUGH?
Data Driven Optimisation
Vestas PowerPlus™
IWPC 2015-Istanbul- April 2015
 Capturing the value of
Vestas’ R&D and
Performance &
Diagnostics Centre to
improve turbines already
installed in the field
IWPC 2015-Istanbul- April 2015
5
4
0
Good
 Focused on upgrades and
solutions that increase
performance and reduce
operating cost and
improve efficiency
200901
200904
200907
200910
200913
200916
200919
200922
200925
200928
200931
200934
200937
200940
200943
200946
200949
200952
201002
201005
201008
201011
201014
201017
201020
201023
201026
201029
201032
201035
201038
201041
201044
201047
201050
201101
201104
201107
201110
201113
201116
201119
201122
201125
201128
201131
201134
201137
201140
201143
201146
201149
201152
201203
201206
201209
201212
201215
201218
201221
201224
201227
201230
201233
201236
201239
201242
201245
201248
201251
201302
201305
201308
201311
201314
201317
201320
201323
201326
201329
201332
201335
201338
201341
201344
201347
201350
LPF [%]
Strategic focus on service and after sales business
Vestas is committed to improving and growing its service and after sales offering
 After sales is an integral
part of Vestas’ growing
service business
Lost Production Factor @
Vestas
6
3
2
1
Vestas is using siting resources throughout the project life cycle
Understanding the climatic conditions on a site is critical
Is this a good site
for wind turbines?
IWPC 2015-Istanbul- April 2015
Can we optimise
these turbine?
Data as decision drivers – start with the best, not with a guess!
Vestas is using siting resources throughout the project life cycle
Unique Global Climate Library
+
26.000 turbines online
+
More than 52.000 turbines installed in 73 countries
+
Close to 4000 met masts
+
Performance and diagnostics data
Intelligent database and super computer resources
IWPC 2015-Istanbul- April 2015
Super
Computer
Facilities
Compute:
1.306 compute nodes
2.612 Intel X5670 CPUs
15.672 X5670 cores
Storage:
2.400TB
3rd largest industrial HPC, PiBs when installed in 2011
Wind Energy O&M Forum - Hamburg - January 2015
From Global to Local...
...from Climate to WTG Performance
IWPC172015-Istanbul2015
From ClimateApril
to Capital
The power of a historical climate library
A unique library of climate data – down to the lowest atmospheric levels
• Mesoscale models
provide us with a
consistent worldwide
coverage of more
than 100 climatic
variables.
• Base resolution 3 x 3
km globally. Data
available, hour by
hour, from Jan. 2000
to present
Combined with 26.000 turbines online and thousands of wind
measurements
Data Driven Decisions
IWPC 2015-Istanbul- April 2015
Powerful match
Site optimisation is combining actual production data with historical mesoscale data
• Vestas PowerPlus™ wind power
plant optimisation is climate
dependent
• Actual production data with onsite measurements is used with
mesoscale data for increased
accuracy
• The result is the best possible
understanding of the climatic
reality on site
IWPC 2015-Istanbul- April 2015
Data drives decision-making
Vestas is evaluating loads and AEP potential turbine by turbine – down to the component
level
• Upgrade-specific load
models ensure that
optimisation is done in
compliance with the
original design loads
envelope
• Load exceedances are
highlighted and mitigated
• Vestas uses a proprietary,
DNV-certified tool –
Vestas Site Check!
IWPC202015-Istanbul- April 2015
When it comes to optimising your wind
power plant – don‘t take chances – trust
the experts with the data!
IWPC 2015-Istanbul- April 2015
Vestas PowerPlus™ - Production Improvement Solutions
Optimised performance of wind turbines and increased annual energy production
Vestas PowerPlus™ is the newly
launched platform for production
improvement solutions
developed by Vestas and
dedicated to the aftermarket.
Up to
5
% Increased annual
energy production*
It currently consists of the
following solutions:
 Power Uprate
 Extended Cut Out
 Aerodynamic Upgrades
Site-specific optimization of
control parameters and
aerodynamic performance
Beyond that, Vestas
PowerPlus™ is a mindset within
the organization. It embodies our
commitment to constantly
improve our existing turbines.
Building on extensive wind
turbine knowledge and
industry-leading R&D
IWPC 2015-Istanbul- April 2015
*Actual AEP increase depends on turbine type and site conditions
Power Uprate
Increase production by fully utilising available load margins

Increase annual energy
production by up to 4%

Increase nominal power of V821.65MW to 1.8MW and V90/1001.8MW up to 2.0MW

Optimise use of available load
margins within certified design
loads envelope

Use Wind Sector Management for
optimal performance on
climatically challenging sites

Turbine- and site-specific loads
and AEP analysis performed by
Vestas

Optimise energy production on
interconnect grid limited site
using PPC to manage output

Combine Power Uprate with
Aerodynamic Upgrades (V82, V90,
V100) and Extended Cut Out
(V100)
IWPC 2015-Istanbul- April 2015
Model Power Curve of up-rated V90-1.8/2.0MW
Example of optimised utilisation of load margins
*Actual AEP increase depends on turbine type and site
conditions
Extended Cut Out
Capture the full potential of strong winds by optimising cut out and re-cut in settings

Increase annual energy production
by up to 2%*

Extend cut out and re-cut in wind
speeds of V100 up to 25m/s and
V90-3MW up to 30m/s

Optimise use of available load
margins within certified design loads
envelope

Turbine- and site-specific loads and
AEP analysis performed by Vestas

Reduce abrupt stops due to high
wind, minimizing stress on drivetrain
parts

No increase in name-plate rating –
full benefit even on interconnect grid
limited sites

Combine Extended Cut Out with
Power Uprate on V100, and
Aerodynamic Upgrades on V90 and
V100 turbines
IWPC 2015-Istanbul- April 2015
Extended cut out on model power curve
Example of production gains on V90-3MW
LAST BUT NOT LEAST
HEALTH
SAFETY
ENVIRONMENT
Wind Energy O&M Forum - Hamburg - January 2015
Thank you for your attention
Copyright Notice
The documents are created by Vestas Wind Systems A/S and contain copyrighted material, trademarks, and other proprietary information. All rights reserved. No part of the documents may be reproduced or copied in any form or by any
means - such as graphic, electronic, or mechanical, including photocopying, taping, or information storage and retrieval systems without the prior written permission of Vestas Wind Systems A/S. The use of these documents by you, or
anyone else authorized by you, is prohibited unless specifically permitted by Vestas Wind Systems A/S. You may not alter or remove any trademark, copyright or other notice from the documents. The documents are provided “as is” and
Vestas Wind Systems A/S shall not have any responsibility or liability whatsoever for the results of use of the documents by you.