Capacity Building in the Field of Wind Energy, Stage II 29 March - 2 April, 2010

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6. Site characteristics
Described by site topography and
site climate change.
To calculate the effects of site
topography on the wind power, it
is necessary to describe the nature
of the site topography i.e.
roughness, Obstacles, and
orography, to understand the
effects of each parameter on the
wind power.
Climate change
B= ρRT
P1 =0.5 X ρ1 X U3

7. Zafarana Wind Farm is located 120km south of Suez on the Red Sea.

8.  Zafarana site
 Flat area 20 km along sea cost,
 Average wind speed 8.5 m/s
 Turbulence intensity lower than 7%,
 Summer windy - prevailing wind direction bounded in Narrow zone

9. Machine technology
 Utility-scale wind turbines for land-based wind farms come in
various sizes, with rotor diameters ranging from about 50 meters to
about 90 meters, and with towers of roughly the same size. A 90-
meter machine. with a 90-meter tower would have a total height
from the tower base to the tip of the rotor of approximately 135
meters.
 Offshore turbine designs now under development will have larger
rotors—at the moment, the largest has a 110-meter rotor
diameter—because it is easier to transport large rotor blades by ship
than by land.
 Small wind turbines intended for residential or small business use
are much smaller. Most have rotor diameters of 8 meters or less
and would be mounted on towers of 40 meters in height or less.

10. Machine technology

11. Wind Farm
Arrangement of arrays inside wind farm is called
(micro-siting) and it is one of the main factors that
improve the wind farm performance because of the
following:
 Reduce wake interaction between turbines each other to
avoid:
- fatigue damage.
- Reduce stress on movement parts ( yaw system, and
blades of turbines)
 Minimize required area maximize energy production of
wind farm.

14. Operation & Maintenance

15. Zafarana
 ‫ﺻﯿﺎﻧﺔ دورﯾﺔ‬TIME BASED MAINTENANCE
H.R.OF
TIME BASED MAINTENANCE FAULTS&
MANF. PLAN NO FEED BACK FAILURE
• ‫ﺻﯿﺎﻧﺔ اﻻﻧﮭﯿﺎرات‬ BREAKDOWN
MAINTENANCE
M.DEP.
MAJOR
FAULTS - FAILURE BREAKDOWN MAINTENANCE NO CORRECTION FAULTS&
FAILURE

16. Total Productive Maintenance
TPM is often presented as a series of pillars supporting Lean
Manufacturing and resting on a foundation of education and
training. Below this is the attitude of environmental responsibility
and safety.

17. Total Productive Maintenance
 Supporting Lean
Maintenance enables and supports Lean efforts in at least three major
ways: Quality, Setup Reduction (SMED) and predictability. In turn,
other Lean elements support TPM through Workcells, Teamwork and Problem-
Problem-
solving.
 The Foundations
Education & Training-- Education, training and investments in people characterize
Training--
all aspects of Lean. In the maintenance area, they are even more important because
of the specialized knowledge required on typical manufacturing equipment. This is
equipment.
one of the foundation stones of TPM. Without it, the pillars of TPM will have limited
impact.
Safety/Environment-- Underlying even the training and education piece are the
Safety/Environment--
more fundamental values of responsibility to the environment and safety for
employees. One important reason is simple: it is the right thing to do.
A more pragmatic reason involves motivation. Most people want to be a part
of something larger than themselves; appeals to higher motivation bring involvement
motivation
and commitment. It is difficult to argue against safety and a common commitment to
common
safety can be a bond that brings people together on other issues.
issues.

18. Zafarana
 ‫ﺻﯿﺎﻧﺔ دورﯾﺔ‬TIME BASED MAINTENANCE
H.R.OF
TIME BASED MAINTENANCE FAULTS&
MANF. PLAN NO FEED BACK FAILURE
• ‫ﺻﯿﺎﻧﺔ اﻻﻧﮭﯿﺎرات‬ BREAKDOWN
MAINTENANCE
M.DEP.
MAJOR
FAULTS - FAILURE BREAKDOWN MAINTENANCE NO CORRECTION FAULTS&
FAILURE

19. Autonomous Maintenance
 Autonomous maintenance is the concept that the people who
operate a machine should maintain the machine. The degree
of autonomous maintenance depends on the level of training and
the abilities of operators. It often starts with basic lubrication,
cleaning and inspection and then graduates to minor or even major
repairs.
 For example, in the foundry where this author worked, machinists
repaired and overhauled their own machine tools. A trained and
competent machinist is certainly capable of overhauling a gearbox.
And, as the users, they tended to know the equipment
intimately. In the military, everyone cleans their own
weapon. When their life depends on proper functioning,
people take more care.
 Autonomous maintenance frees resources in the
maintenance department for the other activities such as
equipment improvement or major overhauls. It amplifies the
maintenance efforts and involves the operators who then take
better care of the equipment.

20. To apply Autonomous
Maintenance
 Reward policy.
 Plan for revamping people in operation not
less than 3 years.
 Interaction between maintenance team
and operation team and highlighting the
problems.
 Information transparency

21.  ‫ﺻﯿﺎﻧﺔ دورﯾﺔ‬AUTONOMUS M.+TIME BASED MAINTENANCE
R.R.OF
SHORT TERM PLAN T B M + A.M FAULTS&
FEED BACK FAILURE
P.CHECK
(PRES.,TEMP.,AMP.,…VIB. CHECK))
(PRES.,TEMP.,AMP.,…
• ‫ﺻﯿﺎﻧﺔ اﻟﺘﺼﺤﯿﺢ‬ CORRECTIVE MAINTENANCE
MINOR
FAULTS&
FAULTS - FAILURE CORRECTIVE MAINTENANCE FEED BACK FAILURE
P.CHECK
(PRES.,TEMP.,AMP.,…VIB. CHECK))
(PRES.,TEMP.,AMP.,…

22. Planned Maintenance
 Planned maintenance is the deliberate planning and scheduling of
maintenance activities as opposed to reacting to breakdowns and
emergencies. A maintenance department that uses TPM effectively
generally devotes less than 10% of its labor hours to such unplanned
activities.
 Without TPM it is not unusual for 80%-90% of the labor to be unplanned.
Unplanned maintenance is a strong indicator that prevention and
improvement programs are non-existent or ineffective.
 In addition, high percentages of unplanned maintenance creates
problems. For example:
 Huge inefficiencies in maintenance labor.
 Confusion and disturbance in scheduling, production and other
areas.
 Morale problems.

23. How to plan all activities
 Activate Reporting
 Build CMMS system
 Activate manufacturer recommendation
 Predictive maintenance
 Check plans

24. PLAN
DO
PLAN
ACTION DO CHECK
CORRECTION & MODFICATION
REG. M. + OVERHAULING
EG. OVERHAULING
ACTION
CHECK
P.CHECK
(PRES.,TEMP.,AMP.,…VIB. CHECK)
(PRES.,TEMP.,AMP.,…
CMS
Aut. M CT T
RE AC
DI NT
CO
DATA

25. New Equipment
Management
New equipment management is related
somewhat to equipment improvement. It refers
to the careful design, selection and testing of
equipment. The purpose is to ensure a smooth
commissioning process with minimal design
defects and problems. New equipment
management includes vendor selection,
evaluating options for maintainability, training
personnel in advance and other common-sense
techniques.

26. Maintenance management
organization

27. Maintenance management
organization

28. Zafarana is a location with extreme conditions the wind turbines that have
been installed have been specially prepared to cope with Egypt’s hot desert
climate, sand storms and salty air. Special seals had to be created to prevent
sand from getting in to the units and rotor-blade cleaning have been planned
for several times per year.

29. To utilize wind power
 Meteorological conditions.
 Location (site topography).
 Machine technology (turbine design).
 Grid connection
 O&M management