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Ministry of Electricity & Energy (MEE)
New & Renewable Energy Authority (NREA)



              Zafarana Wind Farm
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.
ZAFARAN
                                Cairo

Zafarana site location
In the south east of Cairo by
190 km
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
Zafarana Wind Farm
Zafarana - 1 :     30 MW
50 WTG 600 Kw Nordex (N43) Turbines
Zafarana - 2 :     33 MW
55 WTG 600 Kw Nordex (N43) Turbines.

           Nordex = 105 WTG 63 MW

Zafarana - 3 :     30 MW
46 WTG 660 Kw Vestas (V47) Turbine
Zafarana - 4 :     47 MW
71 WTG 660 Kw Vestas (V47) Turbines
           Vestas = 117 WTG 77 MW
Zafarana Wind Farm
Zafarana – 5 :    85 MW
100WTG 850 Kw Gamesa G52 Turbines

Zafarana – 6 :   80 MW
94 WTG 850 Kw Gamesa G52 Turbines

Zafarana – 7 :    120 MW
142WTG 850 Kw Gamesa G52 Turbines

Zafarana – 8 :    120 MW
142WTG 850 Kw Gamesa G52 Turbines

      Gamesa = 478 WTG 405 MW
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
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
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
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
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)
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)
MDT = MWT + MTTR

MWT : Mean Waiting Time
MTTR : Mean Time To Repair

     Availability %

MWT : Mean Waiting Time
MTTR : Mean Time To Repair
Availability statistics for
  Zafarana wind farm


                                                 Nordex




                  Vestas



  Gamesa
                           Real data from Zafarana Control Room
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
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
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
Maintenance Activity
 1- Corrective Maintenance
          (Remedy of unexpected breakdowns)

2- Preventive maintenance
              (Periodical Maintenance )

3- Predictive Maintenance
    (Early detection of failure & planning for repair)
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
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)
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……
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
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
Very Important note:-
 Do not forget to LOCK THE ROTOR before doing any (measuring, re-torque
                lubricating and cleaning …etc) Inside the Hub.
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
Mechanical Tools used on service
Mechanical Tools used on service     Hi-torque Machine


       Hi-torque Device




       For VESTAS Turbine



                                   For NORDEX Turbine
Electrical Devices used on service & trouble shooting




                 Fluke                                  Clamp Amp.




      Transformer. Ratio meter                             Megger
Corrective Maintenance
                  (remedy of unexpected breakdowns)
                                   Faults
         Major                                                Minor

1- Changing Gearboxes, Main bearings,               Daily repair & change
Cardan shafts, break discs, Power cables and
                                               1- Contactors, relays, fuses &
Generators for Nordex turbines.
                                               electrical motors.
                                               2- Electronic cards, CT modules,
2- Changing Gearboxes, Composite shafts,
                                               sensors & softwares
pitch cylinders, Power cables, Generators &
ground controller cabinets for Vestas          3- Hydraulic pumps, valves, oil
turbines.                                      seals & hoses
Changing pitch cylinder for Vestas
Changing gearbox for Nordex
Changing Generator for Vestas
Changing Gearbox for Vestas
Cleaning Heat exchanger for Nordex

             Liquid In


Liquid out



                                    Heat exchanger

 Tank




                            Pump with elec. motor
* Chemical liquid or
  Gasoline are used
    for cleaning
   Heat exchanger

 * The efficiency of
 Heat exchanger is
increased up to 85%
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.
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
Changing Bearings for Vestas Generator
Repairing small elec. motors for Nordex & Vestas
Changing Bearings for Nordex Anemometer
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
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
Vibration device
Dial Gauge
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
Thanks
Best Wishes
  for All

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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
  • 5. Zafarana Wind Farm Zafarana - 1 : 30 MW 50 WTG 600 Kw Nordex (N43) Turbines Zafarana - 2 : 33 MW 55 WTG 600 Kw Nordex (N43) Turbines. Nordex = 105 WTG 63 MW Zafarana - 3 : 30 MW 46 WTG 660 Kw Vestas (V47) Turbine Zafarana - 4 : 47 MW 71 WTG 660 Kw Vestas (V47) Turbines Vestas = 117 WTG 77 MW
  • 6. Zafarana Wind Farm Zafarana – 5 : 85 MW 100WTG 850 Kw Gamesa G52 Turbines Zafarana – 6 : 80 MW 94 WTG 850 Kw Gamesa G52 Turbines Zafarana – 7 : 120 MW 142WTG 850 Kw Gamesa G52 Turbines Zafarana – 8 : 120 MW 142WTG 850 Kw Gamesa G52 Turbines Gamesa = 478 WTG 405 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
  • 14. Availability statistics for Zafarana wind farm Nordex Vestas Gamesa Real data from Zafarana Control Room
  • 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
  • 26. Mechanical Tools used on service
  • 27. Mechanical Tools used on service Hi-torque Machine Hi-torque Device For VESTAS Turbine For NORDEX Turbine
  • 28. Electrical Devices used on service & trouble shooting Fluke Clamp Amp. Transformer. Ratio meter Megger
  • 29. Corrective Maintenance (remedy of unexpected breakdowns) Faults Major Minor 1- Changing Gearboxes, Main bearings, Daily repair & change Cardan shafts, break discs, Power cables and 1- Contactors, relays, fuses & Generators for Nordex turbines. electrical motors. 2- Electronic cards, CT modules, 2- Changing Gearboxes, Composite shafts, sensors & softwares pitch cylinders, Power cables, Generators & ground controller cabinets for Vestas 3- Hydraulic pumps, valves, oil turbines. seals & hoses
  • 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
  • 38. Changing Bearings for Vestas Generator
  • 39. Repairing small elec. motors for Nordex & Vestas
  • 40. Changing Bearings for Nordex Anemometer
  • 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