Johan Prinsloo, IMS International

World Class Windturbine
Maintenance Project
Ir. Johan Prinsloo, Technical Director
A presentation by IMS International
Your partner in Integrated Maintenance & Asset Management Solutions
© Copyright 2014 by IMS International B.V. This presentation, nor any part of it, may be copied,
circulated, quoted, without prior written approval from IMS International B.V.
2014
Introduction
Participants of WCWM
project
ASSET & MAINTENANCE MANAGEMENT SOLUTIONS
From strategy up till operational excellence
Responding to Dutch World Class Maintenance ambition
Taking the engineering & consulting services of KEC and Filanet one step further
Copyright 2014 - IMS International
2
1979
AIR FORCE SECURITY OFFICER
South African Defence Force
(Compulsory Military Duty)
1982
1985
CO-FOUNDED
ANSYS
HIGHER EDUCATION
University of Pretoria
BEng Electronic Engineering
BEng (Hons) Electronic Engineering
DEFENCE
Naval, Army, Air Force projects:
Advanced Weapon Integration,
Avionics , GBADS, Submarine
consoles, Logs Equipment
2007
1987
2009
2011
PRETORIA
ANSYS LISTED ON
THE JHB STOCK
EXCHANGE
FILANET
• Maintenance and
Systems Engineering
• RCM / RAMSHEC
• Digitized Maintenance
Management Systems
• Wind Farm O&M design
• Business Development
consulting –
proposals/negotiation
• Aerospace designs
• Financial modeling
• ……..
TECHNICAL
DIRECTOR/BUSINESS
DEVELOPMENT
SPACE
Satellite interface design,
Launch vehicle interface design
MINING
Rope testing, Maintenance
Management solutions
RAIL
Integrated Train Condition
Monitoring Systems, Vehicle
Identification systems/Tracking,
Locomotive Computer systems
INDUSTRIAL
Maintenance Management
Systems, Condition Based
Monitor Systems
1
Digitized Maintenance Goals
Control room
Maintenance management
& monitoring
Field support
Knowledge management
Consistent data collection
Asset based procedures
Logistics, resources, spares &
tools optimization
Track & trace
Maintenance management
dashboard
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.
handheld
FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS)
Uses Cellular Network (3G, GPRS),
Telephone Modem if cellular network
is not available, or satellite
communication
MMS WEB
PORTAL
Reporting
Planning
Controlling
Scheduling
Metrics
MMS
SERVER
HUB
MMS
ASSET OWNER
PDA
Optimize maintenance
based on consistent,
reliable data.
Incident and problem
management
RFID
Tag
Schedule
maintenance
tasks
Maintenance tasks,
information on logistics,
spare parts and tools
Plan
Routing, maintenance
procedures, safety,
environmental
instructions
Radio
Frequency
HUMS (Health and Usage Monitoring
System) will be installed in the Asset
Environment. HUMS will interface with
the MMS Server via the HUB, and link
into all available Sensors to provide a
real-time
predictive
monitoring
capability.
Do
Act
Just in time , relevant
technical, routing and
logistics information
Remote support
SENSORS
HUMS
Wireless, Radio
Frequency, etc.
HUMS also links with PDA to allow realtime tracking (location) within the HUMS
sensor range.
Automatic Measuring Points
Automatic Sensors
Condition Monitoring Points
Monitoring of
maintenance and
operations
Check
ASSET OWNER
SERVER
Asset Owner uses MMS as
Single Integrated Predictive
Maintenance Management
Solution
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.
Feed back of
maintenance data,
completed tasks,
inspection data, pictures,
parameters, data of
remote sensors
FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS)
Digitized into 345 consistent tasks and 3 scheduling levels
DELTA
WT MAINTENANCE
AND INSPECTION
SCHEDULES
Knowledge
management
FILANET
MAINTENANCE MANAGEMENT
SYSTEM (MMS) WEB PORTAL
Filanet supplied Handheld
Knowledge
management
Delta / Oliveira
Control Room / Management Dashboard
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.
Delta OLAZ II
Live Pilot Tests performed
in Q4 2012 & Q3/Q4 2013
by Delta technicians
Owner Inspection for
Kreekrak Q1 2014
FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS)
• WT (OLAZ II – Vestas V47) Maintenance / Inspection Schedules fully digitized and available through the webbased MMS portal (345 tasks, 3 scheduling levels).
• WT (Kreekrak) owner inspection fully digitized and available (449 tasks, 3 scheduling levels)
• Live testing performed by Delta technicians in Q4 2012, Q3/Q4 2013 and Q1 2014 using the Filanet supplied
handheld and tasks loaded via the MMS portal.
• Use of handheld / web solution for maintenance / inspection confirmed, however, several lessons learned in the
process.
• Excel based reporting functionality
• Interface to management dashboard and Delta OPS data developed
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.
FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS)
MMS Web Portal – Screenshot 1 (shows status of high level scheduled tasks)
Completed Tasks, shows status (Green = no issues,
Red = Issues to be resolved)
See next slide for detail of Task ID 10543
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.
Excel Generated Reports
FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS)
MMS Web Portal – Screenshot 2 (shows status of Task ID 10543)
Specific task not completed successfully, requires
further action from Delta technicians
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.
FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS)
MMS Web Portal – Screenshot 3 (Shows details of Excel Generated Report for Task ID 10543)
Detail fields of the Excel report will form the
basis of the data inputs from the Filanet
MMS solution to the Delta Oliveira Control
Tower / Management Dashboard.
From the data a consistent database will be
populated that will show completed
maintenance / inspections and open issues.
This will also allow for engineering analysis
to be performed on the open issues (spare
parts analysis, root cause analysis, revised
maintenance / inspection profiles, etc.),
and for automatic generated reports to be
issued to internal staff and / or external
repair / parts suppliers to address the open
issues.
Pictures
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.
FILANET MAINTENANCE MANAGEMENT SYSTEM (MMS)
LESSONS LEARNED:
• Filanet MMS software was developed in sequential format (one task scheduled after the other and
requires a task to be completed prior to moving to the other, flexibility provided in the way the tasks
are scheduled, therefore the 3 levels of scheduling [all tasks at once; section per section; sections
within each section). Based on the maintenance / inspections routes used by the technicians through
the live pilot it became clear that the software needs to be more flexible to allow technicians to
complete individual tasks without having to be forced in a sequential manner.
• Filanet MMS system was initially set on active communications with the web portal (as tasks are
completed they are transferred in real time to the server for display, and scheduled tasks are
downloaded in real time when the user logs onto the handheld). Due to the wind turbine metal
structure real-time communications are not available at all times and this upsets the workings of the
solution in terms of data uploads and downloads. The issue was resolved for the pilot whereby manual
uploads and downloads are performed, however, for long term solutions the issues of real-time, or
near-real time communications, requires further investigation and implementations.
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.
FILANET RELIABILITY CENTERED MAINTENANCE (RCM) – SLIDE 1/3
• Phase 1–
System Identification and Function Definition for Vestas V47 (OLAZ II).
• Phase 2–
Failure Mode and Effect Criticality Analysis (FMECA) based on data from phase 1.
• Phase 3–
Identification of high risk items and using the decision logic tree with feedback into the current
maintenance concept to assess improvements.
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.
FILANET RELIABILITY CENTERED MAINTENANCE (RCM) – SLIDE 2/3
Agreed RCM Process for Delta V47 OLAZ II
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.
FILANET RELIABILITY CENTERED MAINTENANCE (RCM) – SLIDE 3/3
LESSONS LEARNED:
•
The Vestas V47 (OLAZ II) is a highly reliable turbine. The application of the RCM process is limited in its ability to
influence the current maintenance profile. The prime benefit of the RCM during the pilot is allowing the
technicians and management to think of the turbine in terms of its functions, and the effect of loosing the
functions, rather on pure failure of components and systems. This assists in finding the root causes of problems
and cost effectively addressing them rather than spending large amounts of replacing components and parts. The
RCM process is also a good learning and personal development process for the Delta staff and allow them to
seamlessly apply the process to turbines that exhibits constant problems and failures.
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.
IMMS Android App
Asset Management Specialist Edition
Welcome J. Prinsloo
V1.0
Welcome J. Prinsloo
IMMS Maintenance Manager
Welcome J. Prinsloo
Asset Management Specialist Edition
V1.0
Further development towards asset
& maintenance management
solutions by IMS International
More information during the
afternoon session
ASSET & MAINTENANCE MANAGEMENT SOLUTIONS
15
Mede gefinancierd door de provincies Zeeland en Noord-Brabant en het Ministerie van Economische Zaken, Landbouw en Innovatie.

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