Guy Van Roy Product manager Digitalization ZF Windpower · GEARBOX EXPERTISE FAILURE MODES &...

CONFERENCE BELGIAN OFFSHORE DAYS | Servitisation and digitization trend in Offshore Wind

Services Powered by Analytics

Guy Van Roy

Product manager Digitalization

ZF Windpower

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3. Gearbox digital birth certificate

Motivation: Reducing levelized cost of energy

5. Alert Based Recommendations

Consumed life time calculation

Reliability and remaining life time

Spare parts recommendations

Agenda

1. ZF History

4. Motivation: Reducing levelized cost of energy

ZF history

First windGearbox

2MWGearbox

8MWGearbox

Spare partsOptimization

PlanetaryGearbox

3MWGearbox

ModularGearbox

1979 1998 2013 2018

1993 2002 2016

ZF historyData

2017


Alert HandlingInclusion

New operationalService models

New SensorSolutions

40 years of experience

Gearbox designSensors and monitoring

Services


LCOE Drivers

CAPEX

Enable lifetime extension

Value engineering

Financial risk analytics

AEP

Spare parts optimization

Fast return to operation

Enable power upgrades

OPEXReliable & efficient operation

Reduce spare parts inventory costs


CONVENIENCEEasily accessible, online O&M documentation

Fixed pricing for Genuine

ZF parts

Reduce spare parts inventory costs

Easy access for service crews to up-to-date gearbox

documentation, technical manuals and spare parts lists.

Throughout the contract, get access to Genuine ZF spare parts and services at upfront agreed prices.

Optimize the in-time spare parts planning for your fleet.

TRANSPARENCY

COST REDUCTION

VALUE HOW

Enable fast turbine return-to-operation

Avoid long turbine downtime by making sure the right spare parts are available when and where they are needed.

REDUCED DOWNTIME

Motivation: Reducing levelized cost of energy - Analytics

REMAINING LIFETIME CONSUMED LIFETIME

Reliability statistics Reliability calculations

1-

RE

LIA

BIL

ITY

Spare Parts Recommendations

GEARBOX EXPERTISE

Motivation: Reducing levelized cost of energy - Data

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Agenda

1. ZF History

4. Life Cycle Monitor

Convenience

Spare Parts lists O&M Documentation

DIGITAL BIRTH CERTIFICATE

DESIGN MODEL

GEARBOX EXPERTISEFAILURE MODES & SOLUTIONS

Used in consumed lifetime calculation

Used to link spare part kits to failure types

AS-BUILT INFORMATION

Used to link failure types to technical solutions

Available to turbine owner in digital format

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5. Summary – Services powered by Analytics: Spare parts optimization




Agenda

1. ZF History


• Uses design models and SCADA data to calculate the consumed lifetime for every major gearbox component

• No extra proprietary hardware needs to be installed up-tower

Life Cycle monitoring based on SCADA data

Analytics: Consumed life time calculation

• Cloud calculation according to IEC 61400-4:2012 Design requirements for wind turbine gearboxes

• Includes all relevant normed calculations• Gear root bending fatigue• Gear flank pitting fatigue• Bearing subsurface pitting fatigue

• Uses the actual loads of an individual turbine instead of the simulated design envelope loads

Summary – Services powered by Analytics: Spare part optimization

CONSUMED LIFETIME

REMAINING LIFETIME

LOAD AND SPEED DESIGN MODEL CONSUMEDLIFETIME

ZF SERVICEINTERVENTION DATA

CLASSIFICATIONBASED ON DOMAIN

KNOWLEDGE

REMAININGLIFETIME

SPARE PARTSRECOMMENDATIONS

EXTERNAL SERVICEINTERVENTION DATA


The calculations show the consumed lifetime relative to the design limits for wind turbine gearboxes as defined in “IEC 61400-4:2012 Design requirements for wind turbine gearboxes”

Calculation is performed for every gear and bearing in the gearbox, for the loads of each individual turbine

Covers the wear-out / fatigue part of the calculable failure modes in the reliability plot

Analytics: Consumed life time calculation

CONSUMED LIFETIME

Prognosis towards the future

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Agenda

1. ZF History


• More than 110 GW of installed base• Unique historical expertise and insight

in gearbox performance• Reliability expertise based on historical

root cause investigation• Access to original design models

More than 40 years of experience

Analytics: Reliability and remaining life time

ZF SERVICE INTERVENTION DATA

Conversion of all historic ZF interventions into standard taxonomies• Enables a common view on all assets delivered by ZF

• Hansen Transmissions legacy products• ZF legacy products• Bosch Rexroth legacy products

• More than 55,000 gearboxes shipped• Covering 25% of the globally installed base• ZF powers more than 50% of the global 3 MW onshore installations • Integrates domain knowledge to the data

• Failure cases (8D, DMAIC, …)• Root cause analysis• Permanent corrective actions

• Requires integration or migration of data sources (e.g. SAP master data)

Analytics: Reliability and remaining life time

REMAININGLIFETIME


• Large statistical database enables accurate model parameter estimation• Multiple statistical models possible, for example the 3 parameter Weibull

• Gearbox expertise and asset taxonomy allows applying the fitted models on a small population (e.g. a specific wind park)

What was the technical solution to this problem?Is it implemented on the gearbox under analysis?

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Agenda

1. ZF History



SPARE PARTSRECOMMENDATIONS


• Linking failure types and solutions to spare part kits and upgrades allows accurate recommendations• Each failure type has its own solution, but it also depends on the asset version• Recommendations can be dependent on lead-time of the spare parts

GEARBOX EXPERTISE

• Specific gearboxes might not require a spare part because they have the solution to the root cause implemented, the data model keeps track of this

Spare Parts Recommendations

SPARE PARTS RECOMMENDATIONS

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Agenda

1. ZF History


Services Powered By Analytics

ALERT BASED RECOMMENDATIONS

Combination of CMS alarms with gearbox experience

CMS as enabler for predictive mainentanceCMS has become state-of-the-art for modern wind turbinesAlarm & trend monitoring

Evolution to „autonomous wind turbines“

Services Powered By Analytics

ALERT BASED RECOMMENDATIONS: VIBRATION CMS

Summary – Services powered by Analytics: Spare part optimization

Consumed lifetime• ZF can calculate the consumed lifetime on an individual turbine using SCADA data or DLM data

Remaining lifetime• ZF leverages data that already covers over 25% of the global installed base to generate accurate statistics

• The data is mapped to an industry standard, to enable enhancing the data with external sources• The statistics can be applied on individual turbines, using detailed domain knowledge

When combining consumed and remaining lifetime, ZF can make accurate spare part forecasts• This will minimize downtime and optimize your OPEX costs

Adding the alert support, ZF gives you the capability to reduce your “return to service”

And thus enable you to reduce the Levelized Cost of Energy of your wind turbine assets

This is only the first step in the Digitalization processes at ZF wind power…


Thank YouFor Your Attention

[email protected]

Guy Van Roy Product manager Digitalization ZF Windpower · GEARBOX EXPERTISE FAILURE MODES &...

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