Title of the Presentation - · PDF fileFailure mode (affected area, ... GL-DNV CERTIFIED Life Extension ... FEM studies that allow to optimize inspection costs

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Life ExtensionAgeing Fleet Management

December 2014

SERVICE SALES DEPARTMENT

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Life Extension

Wind turbines were designed, calculated and certified for 20 years of service life under design standards.

Such conditions are usually conservative compared to Wind Farm met mast data.

Wind Farm operation inputs, together with product knowledge allows to evaluate the impact on each substructure of each WTG.

Overview

Ageing factors

Fatigue loads

Structure Design

Knowledge

Ageing

mechanism

Failure mode (affected

area, life expected)

Life extension

solutions

Availability 98%

Safety for people and assets

Stabilized O&M cost

Operative Experience

Operational life

Probability

Years

Initial

design

condition

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Life Extension

1. Recalculating loads under customized conditions (specific site assessment). a. Real operation register-logs, b. Specific WF assessment (sub-groups depending on

components, i.e.Foundation)c. allowing to maximize productivity while

optimizing maintenance costs (Gamesa developed tools created for optimizing analysis)

2. Updated state of the art: FEM analysis instead of analytical where applicable.

3. Recalculate under updated standards: Focusing specifically (but not only) in the safe operation for both installation and personnel.

4. Corroborated with Gamesa O&M operative experience (failure rates on main components)

5. Certified by a 3rd party: Gamesa is the 1st OEM worldwide in certifying Life Extension under GL2009 Continued Operation Guidelines

Program structure followed

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Título presentación / Presentation Title

Life Extension


WIND CONDITIONS

- Air density- Average speed- Shear- Upflow- Turbulence intensity- Weibull parameters

CONTROL

- Yaw misalignment- Particualr operating

conditions (i.e. longstop periods)

WTG MODEL

- Catia model- Aerodynamics- Component envelope(i.e. gearbox weight, natural frequenciesaffection)

AEROLASTIC LOADS ANALYSISSite specific conditions

LIFE DETECTION ANALYSISAnalysis per subcomponent

Critical load pathConsumables failure rate

LIFE EXTENSION MANAGEMENTAdapted to site specific analysis

Inspections-surveillance (if required)Design modifications (if required)

Optimized O&M costs - investments

ADDITIONAL INFO

As Built

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Life Extension

Scope of analysis

Loads analysis Site specific

assessment for WF categorization (complex site /moderate)

Load factors cases according to state-of-the-art

Safety

Equipment and personnel complete assessmentaccording GL2010

Blades

Calculation accordingupdated standards

Blade tests safety margins

Machinerycomponents

FEM analysis per subcomponent

Electricalcomponents

FMEA for protections Earthing Lightining protection

Tower

FEM analysis Crack growth

analysis determine inspection intervals

Nacelle cover

Live loads Extreme Wind

conditions

Foundation

Specific siteassessment

As-built informationrequired

Specific inspectionmethodology

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Wind Data

LOADS

FE models

COMPONENTS STRUCTURAL

ANALYSIS

Inspection plans

New tasks/ maintenance

programs

Repair/Reinforcement/Substitution of

components

OPERATIVE EXPERIENCE

GL-DNVCERTIFIED

Life Extension


Site assessmentknowledge

Real Wind setsS1 & S2

Life consumed

GL guidelines& updatedstandards

Reliable characterization of each WF

Optimized calculusregarding previouscalculation

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Mathematical Models

Ageing and Life Extension Management

Standard followed:

GL2009 Continued Operation

GuidelinesSet of loads S1/S2 (Mx,My,Mz,Fx,Fy,Fz)

FEM CALCULUS (According IEC 61400-1)

OKFEM CALCULUS

(INSPECTION REQUIRED)

REDESIGN/REPAIR OK

Sets of loads:

S1: Medium

S2=Severe

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► Physical properties based on international standards or experimental data from component tests.

► Material properties based on main international standards (IEC61400-1, ISO2394, EN1993-1-10:2005)

► The required number [n] of in-service inpections defined according 1993-1-9

Life Extension

Material and Processes design inputs

Crack geometricfactor (shape)

INSPECTION INTERVAL

Minimum indication detected (method)

Material properties (ductility)

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After several years of operation, some components – depending onsome factors - such as particular wind conditions of the WF- mightbegin experiencing faults arising due to fatigue accumulation.

A CMS for monitoring the condition of certain WTG componentshas been analyzed in terms of technical viability (state-of-the-art) andcosts.

The real time monitoring is chosen where it provides costssavings and/or technical advantage with regards toinspections (i.e. SMP, bearing temperature continuous monitoring)

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DESIGN LIFEEXTENDE

D LIFE

YEARS0 30

Inspections- monitoring


Gearbox and generatormonitoring system(Gamesa SMP –GL certificate)

Inspection procedures, where applicable, are based on: FEM studies that allow to optimize inspection costs (i.e. tower) Crack propagation studies have been performed to ensure:

Safe inspection frequencies Appropriate inspection methodology (dye test, UT,

visual) depending on crack length and expected crackgrowth.

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Damage

propagation

If a damage condition is detected, we can redesign solutions for the component to last through the extended period.

Fatigue

Damage

Miner = 1

Component redesign

Period in Secure conditions

<20 years Time30 years


Design solutions for continued WTG operation

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O&M Costs

20 years 30 years

Design LifeInitial Stage Extended Life

O&M Costs - Mature IndustriesO&M Costs - Wind Industry

Income

Value creation

Life Extension

Evolution of O&M Costs

Optimize O&M costs – Inspect & redesign the sooner the better

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The results from mathematical models are correlated with O&M information and root cause analyses.

This on-site and long term experience is key in :- validation and fine tuning of the mathematical models.- Identifying inspection methodology that best fit failure mode- redesign if required, focused in critical areas.

Operating Experience data and analysis


20 000 MW maintained, Gamesa and non-Gamesa turbines

TOTAL 2013

MW inst MW O&M Availability*

850 kW 8,598

16,484

700 kW 2,032

98.57%

2.0 MW

98.56%

98.05%

5,456

12,336

1,206

* Annual weighted availability figures.

Take away: Operating experience correlates mathematical model results

with reality.

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1. INPUTS REQUIRED

2. ENGINEERING CUSTOMIZED

ANALYSIS

4. CUSTOMIZED MAINTENANCE

PROGRAM

Realistic failure rates complement theoretical study and

define component reinforcements

3. OPERATIVE EXPERIENCE

Wind data accordingIEC (at least 1yr)

Foundation “As built”

WF REAL LOADS OBTAINED

Life Extension

Specific WF assessment

5. SPECIFIC BUSINESS CASE

Costs savings inspecting and reinforcing only if required

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START UPON-LINE

SURVEILLANCE

ENGINEERING

ANALYSISACTIONS

LIFE EXTENSION

VIABILITY

- Modify inspection frequencies

- Reinforcements based on FEM analysis…

MET DATA-SCADA

INSPECTION

FEM


Specific WF assessment

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../../../Documents and Settings/Dfranco/Configuración local/PREDICTIVO/POWERPOINT/Condition Monitoring Report_v1_En.pdf

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What is the aim of Life Extension

program?

The Life Extension program is linked to a specific engineeringanalysis customized to each WF.

Life extension program is focused to optimize revenues based onlong-term containment of O&M costs.

This program enhances efficiency and cost optimization along LifeExtension period.

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La experiencia de Gamesa en su gestión de la Propiedad Industrial: 2004-2013

Disclaimer

The present document, its content, its annexes and/or amendments (the “Document”) has been drawn up by GAMESA CORPORACIÓN TECNOLÓGICA, S.A. (“Gamesa”) for information purposes only, and contains private and confidential information regarding Gamesa and its subsidiaries (the “Company”), directed exclusively to its addressee. Therefore it must not be disclosed, published or distributed, partially or totally, without the prior written consent of Gamesa, and in any case expressly indicating the fact that Gamesa is the owner of all the intellectual property.

All the content of the Document, whether it is texts, images, brands, trademarks, combination of colours or any other element, its structure and design, the selection and way of presenting the information, are protected by intellectual and industrial property rights owned by Gamesa, that the addressee of the Document must respect.

In particular (notwithstanding the general confidentiality obligation), the addressee shall not reproduce (except for private use), copy, transform, distribute or publish to any other third party, any of the information, totally or partially.

DNV GL © 2013 05th May 2014

Questions

Answers


DNV GL © 2013 05th May 201405th May 2014

Thank you
