James Parle: 2013 Sandia Wind Plant Reliability Workshop
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Innovative Wind Maintenance Management CMMS
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James Parle: 2013 Sandia Wind Plant Reliability Workshop
- 1. Innovative Wind Maintenance Management CMMS Innovative Wind Maintenance Management CMMS James Parle Muir Data Systems James Parle Muir Data Systems
- 3. Road MapRoad Map CMMS overview Wind CMMS Preliminary survey findings Moving forward
- 5. Example CMMS Savings without MobileExample CMMS Savings without Mobile Company Benefit Savings Improve production capacity (maintenance efficiency) 5 – 15% Increase equipment efficiency 20% Increase in production (preventative maintenance) 40% Reduce maintenance budget 30% Reduce production downtime 20% Reduce maintenance labor costs (better scheduling) 10 – 30% Reduction in overtime 10 – 50% Labor productivity increase 30% Inventory cost reduction 25% Decrease maintenance material cost 20% Source: industry benchmarks A.T. Kearny, Grant Thornton, PWC, Gartner, ARC, Tomkins, DOE 15 – 50% O&M Savings
- 6. Oil & Gas CMMSOil & Gas CMMS Source: Siemens Oil & Gas
- 7. Hydro Asset Management Partnership (HydroAMP) Hydro Asset Management Partnership (HydroAMP) Evaluation Method Data standard Single database Plant / utility reports Open to all users
- 8. Expanding US Wind MarketExpanding US Wind Market 28% Growth $50B End of Warranty 30% Spent on Maintenance $6B O&M 2025 0 10,000 20,000 30,000 40,000 50,000 60,000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 WindCapacity(MW) Year
- 9. Current Solution Highly DatedCurrent Solution Highly Dated
- 10. Wind CMMS OverviewWind CMMS Overview
- 11. Why Wind CMMS?Why Wind CMMS? Harsh Environmental Conditions Remote Locations Lots of Moving Parts Highly Distributed Safety Concerns
- 12. Complete Maintenance Management SolutionComplete Maintenance Management Solution Tablet Management Office Cloud Server Analytics
- 13. Enterprise Mgmt. GridSCADA Data Blades TowerNacelleGeneratorGearbox API Maintenance Management Solution DetailsMaintenance Management Solution Details CMMS Infrastructure / Database / Analysis Data Sharing Data Source: Tablet in the Field Data Source: Tablet in the Field Data MovementData Movement Data In-Take Software Modules Data In-Take Software Modules
- 14. Large Scale Data AggregationLarge Scale Data Aggregation Plant 1 Plant 2 Plant 1 Plant 3 Plant 2 Plant 2 Plant 4 Plant 3 Plant 1 Owner 1Owner 1 Owner 2Owner 2 Owner 3Owner 3 Predictive Maintenance Anonymous Data Aggregation System Predictive Maintenance Anonymous Data Aggregation System
- 15. Predictive Maintenance ValuePredictive Maintenance Value 47% O&M Cost Reduction47% O&M Cost Reduction Source: Electric Power Research Institute
- 16. Preliminary Survey FindingsPreliminary Survey Findings
- 17. Survey OverviewSurvey Overview Field Data Office Storage Reporting Demographics Technology · Time · SatisfactionTechnology · Time · Satisfaction
- 18. Company TypeCompany Type Mainly ISPs & OOsMainly ISPs & OOs
- 19. Current PositionCurrent Position More Engineers than ExpectedMore Engineers than Expected
- 20. Company SizeCompany Size Highly Fragmented IndustryHighly Fragmented Industry
- 21. Work Orders per YearWork Orders per Year Average 10 Work Orders per DayAverage 10 Work Orders per Day
- 22. Time in Current PositionTime in Current Position 60% Changed Job Title in Last 2 Years60% Changed Job Title in Last 2 Years
- 23. Work Order Process ChangesWork Order Process Changes 72% Change Annually or Less Often72% Change Annually or Less Often
- 24. Work Order AccuracyWork Order Accuracy Not Good for AnalysisNot Good for Analysis
- 25. Work Order AnalysisWork Order Analysis Limited Analysis PerformedLimited Analysis Performed
- 26. Work Order AnalysisWork Order Analysis 0 3 5 0.00 2.50 5.00 Field Office Storage Reporting 0 30 60 SatisfactionSatisfaction TimeTime TechnologyTechnology Extremely Moderately Not at all Analog Digital Somewhat Digital 0 Mins 30 Mins 60 Mins
- 27. Satisfaction vs. Employee TypeSatisfaction vs. Employee Type 0.00 2.50 5.00 Field Office Storage Reporting Technicians Engineers Managers Executives Moderately Not at all Extremely
- 28. Technology vs. Company TypeTechnology vs. Company Type 0 2.5 5 Field Office Storage Reporting ISP OO OEM Digital Somewhat Digital Analog
- 29. CMMS Company PrioritiesCMMS Company Priorities 0 3 6 Reduced inventory costs Customer satisfaction Increased uptime Greater accuracy Predictive analysis Scheduling ISP OO OEM Aveage Linear (Aveage) Least important Somewhat important Most important
- 30. Wind CMMS LandscapeWind CMMS Landscape INDUSTRY SPECIFIC INDUSTRY SPECIFIC INDUSTRY AGNOSTIC INDUSTRY AGNOSTIC LOW COST LOW COST HIGH COST HIGH COST Generic Low CostGeneric Low Cost Generic High CostGeneric High Cost In-House SolutionsIn-House Solutions Wind Specific Low CostWind Specific Low Cost
- 32. Cultural Shift RequiredCultural Shift Required
- 33. Demand Better SolutionsDemand Better Solutions CMMS reduces O&M costs Technology is ready Wind lagging behind other industries Data becoming competitive advantage Predictive maintenance is the prize
- 34. Offshore Wind CMMSOffshore Wind CMMS