Arab Region Progress in Sustainable Energy Challenges and Opportunities
Capacity building 2010 day 1 maintenance activity
1. Ministry of Electricity & Energy (MEE)
New & Renewable Energy Authority (NREA)
Zafarana Wind Farm
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. ZAFARAN
Cairo
Zafarana site location
In the south east of Cairo by
190 km
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
7. Zafarana Wind Farm
Nordex turbines 10 years of operation
started at end of 2000
Vestas turbines 7 years of operation
started at beginning of 2003
Gamesa turbines 4 years of operation
started at end of 2006
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. Zafarana Wind Farm
The Concept of Maintenance
Main objective of maintenance is to run the machine
safely and minimize damages & breakdown times in
order to achieve maximum benefit from the operation
of the machine.
Good Good Much
Maintenance = availability
= power
10. Maintenance & Tolerance
Maintenance Degree of overtaking
(Tolerance)
Daily None
Weekly ± 1 Day
Monthly ± 3 Day
Quarter year ± 1 Week
Half year ± 2 Weeks
Yearly ± One month
11. Maintenance Obstacles
1- 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. 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. MDT = MWT + MTTR
MWT : Mean Waiting Time
MTTR : Mean Time To Repair
Availability %
MWT : Mean Waiting Time
MTTR : Mean Time To Repair
15. Availability 2007
100%
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. Availability 2008
100%
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. Availability 2009
100%
0.96
0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95
95%
90%
0.85
85%
80%
75%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
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. Life Cycle Coast & Maintenance types
L.E
Corrective Maintenance
Coasts
Preventive Maintenance
Predictive Maintenance
Life time Machine Machine Machine Years
Failure 1 Failure 2 Failure 3
20. General precautions
1- 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, clamp
amps.,……..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. 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. Preventive maintenance (Periodical Maintenance )
Routine Maintenance
VESTAS
MAINTENANCE
TYPES
Cleaning 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. 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. Very Important note:-
Do not forget to LOCK THE ROTOR before doing any (measuring, re-torque
lubricating and cleaning …etc) Inside the Hub.
25. Inspection During Maintenance
Look & observe Ask
For For
Leakage & 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
34. Cleaning Heat exchanger for Nordex
Liquid In
Liquid out
Heat exchanger
Tank
Pump with elec. motor
35. * Chemical liquid or
Gasoline are used
for cleaning
Heat exchanger
* The efficiency of
Heat exchanger is
increased up to 85%
36. Corrective Maintenance
(local repair for defective parts)
1- Rehabilitation of gearboxes (changing bearings) at Z workshop
2- Rehabilitation of generators (changing bearings) at Z workshop
3- Rehabilitation of generators (rewinding) at ABB & Gamma Co.
For Nordex turbines
4- Rehabilitation of generators (rewinding) at ABB & Gamma Co.
For Vestas turbines
5- Repairing small elec. motors
(rewinding + change bearing) at Z workshop.
6- Repairing Electronic cards for (WP 3000, WP 2035) & wind sensor s.
37. Changing Bearings for Nordex Gearbox
Turning Gearbox other side for dismounting
High speed shaft
Gearbox is ready
Reinstalling bearings andbearings Gearbox Parts
Planetary mounting
Bearings for intermediate
41. Predictive Maintenance
(Early detection of failure & planning for repair)
All modern turbines are equipped with a lot of sensors for monit oring
different functions. ( Temperature sensors, filter choked sensor s and
vibration 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. Temp. Sensors
Wind Van
Top box
Anemometer
Monitoring 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
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 important
3- Spare parts (Major – Minor) available when needed.
Enough stock at store house