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Voith Industrial Services Wind
GmbH
Presentation vindmøller i udland
Fredericia 14.10.10
Voith Industrial Services Wind | 20090408 | 2
Profit from Operations € in million Sales € in million
Dynamic growth and solid profits
over decades
We have stronger growth than many
listed companies
Positive results even in times of
recession
Voith Industrial Services Wind | 20090408 | 3
Profit from Operations € in million Sales € in million
Voith Turbo
24%
Voith Hydro
22%
34%
Voith Paper
20%
Voith Industrial Services
Sales
Sales and Employees 2008/2009
by Division
Voith Hydro: € 1,085 million
4,681 employees
Voith Industrial Services: € 1,018 million
19,118 employees
Voith Paper: € 1,743 million
9,500 employees
Voith Turbo: € 1,232 million
5,428 employees
Voith Industrial Services Wind | 20090408 | 4
Voith is innovative
Voith – Where smart people like to
work
11,000 active patents
400 new patents every year
Voith Industrial Services Wind | | 5
Our fields of activities
Voith Industrial Services Wind specializes in providing complete process services for
wind power plants: from single wind installations to wind farms.
Onshore customer groups and plant types served:
Private Owners and Operators
Investment companies (Funds)
Independent Power Producers (IPP)
Electric utilities
Wind turbine manufacturers
Voith Industrial Services Wind | | 6
The business model of Voith
What does Voith accomplish to be the first choice of the customers?
Voith as service provider at OEM stage for large WTG´s till 3 MW
Full line provider incl. general repair + frequency converter
Expertise by experienced employees with OEM´s
Quick response time by remote monitoring of WTG´s (24/7)
Flexible logistics concept: guarantee of availability for spare parts
Cost certainty by long-term frame and service contracts
Decentralized service pojnts (close-by wind farms)
Beirat VIWS |Hamburg 2010-08-06 | 7
Know-how for complex technology: our WTG portfolio
Voith supplies service for over 600 MW of 7 different OEM:
Nordex/ Südwind
Vestas/ NEG Micon
Gamesa Eolica
Siemens Windpower
GE/ Enron/ Tacke
DeWind
E.n.o. Energy
VIWS - Übersicht Bestandsanlagen
(Stand: 31.07.2010)
Siemens
4%
(4%)
Nordex
35%
(42%)
DeWind
24%
(20%)
GE / Tacke
9%
(16%)
Vestas / NEG
Micon
25%
(18%)
Gamesa
3%
(0%)
Voith Industrial Services Wind | | 8
WTG portfolio of more than 30 different types:
DeWind D4
DeWind D6
(1 MW)
DeWind D6
(1,25 MW)
Vestas / Gamesa DeWind GE Wind Siemens Nordex
Tacke TW 600
Tacke TW 600e
NM 64c
NM 72c
NM 82
Nordex N 60/62
Südwind S 70/77
(incl. MD 70/77)
V 80/ V82
(incl. Gamesa G80)
AN Bonus 1,3 MW
GE 1,5 Series
(incl. Tacke &
ENRON)
AN Bonus 450 KW
AN Bonus 600 KW
AN Bonus 1 MW
AN Bonus 2,3 MW
M 1500/1800
NM 48 / NM 52
NM 60
V 39/ V 47/ V 52
Nordex N 80/ 90
2.500 kW
Nordex N 27/29
Nordex N 43
Nordex N 50
Nordex N 52/54 till
1 M
W
till
1,5
MW
ti
ll 2
,5 M
W
DeWind D8
DeWind D8.2
(2 MW)
GE 2.X Series
Voith Industrial Services Wind | | 9
Quality What is going wrong in maintenance of windturbines ?
old maintenance manuals
old or no work instructions
no certified processes (ISO 9001/14001/OHSAS 18001)
unscheduled repairs reduce technical availability
unqualified personnel
insufficient (regular) training
non availability of spare parts
response times and response quality in monitoring
unproper documentation of executed works
escalation processes do not exist
Insuffcient insurance & claim management
Result: Insufficient Technical Availability, poor performance
Monteurstreffen VIWS 2010| 10
Quality What is Quality Management ?
Up-to-date maintenance manuals
Proper work instructions
Certified processes (ISO 9001/14001/OHSAS 18001)
(Preventive) turbine audits
Team audits
Regular training
Regional dedication of teams
Training of monitoring staff for „intensive care“ of turbines
Electronical documentation
Efficient escalation processes
Efficient Insurance & Claim Management
Monteurstreffen VIWS 2010| 11
Quality management Product management: Escalation processes
Vestas/NEG Micon
Roman Müller
Mario Zengerling
(Team Thüringen I)
Siemens/AN Bonus
Thomas Kühnrich
Jan Linke
(Team Lübeck II)
MD70/77 Baureihe
Mario Bemerl
Peter Schüler
(Team Düren)
Nordex
Thomas Kellermann
Sven Gerke
(Team Karstädt)
DeWind
Andreas Bauer
Marko Nitschke
(Team Bremen)
Gamesa
Roman Müller
Avelion Fernández
(Team
Ludwigshafen)
GE / Enron / Tacke
Jens Monsees
Martin Lewinske
(Team Heide)
1st Level Support
„Product manager/
Technician“
Team reports
Problem
2nd Level Support
„Productmanager
Project leader“
3rd Level Support
Engineering
Monteurstreffen VIWS 2010| 12
Background:
Knowledge of variations of different OEM
escalation processes
Goal:
clear responsibilities
bundling of technology - Know-how by accumulation of technician‘s and backoffice
know-how
Transparency for all participants in process
Product management: Why?
Konsequenz: je Technologie ein verantwortliches Team
aus Projektleiter und Monteur
Monteurstreffen VIWS 2010| 13
Quality management Modular training concept
Voith Industrial Services Wind | | 14
Region-wide service network in Germany
continuous development of the
service points in Germany
Number of service points: 15
Number of service teams: 30
Voith Industrial Services Wind | | 15
Maintenance Management The Voith Remote Monitoring Concept
24/7 reactive remote monitoring
24/7 active remote monitoring
Servicehotline
Management of the service intervention
3-shift-system
Voith Industrial Services Wind | | 16
acquisition of customer personal data
acquisition of the supervised wind farms
acquisition of the failures
Maintenance Management WIS - Database
daily planning of the serviceteams
three times a day: verification of the WTG´s
Voith Industrial Services Wind | | 17
Flexible logistics concept: guarantee of availability for critical spare parts
Voith Industrial Services Wind | | 18
Based on availability maintenance planning by using the IMS-system with life
cycle datas of all WTG´s & components
condition monitoring
defined escalation process in order to reduce downtimes to minimum
wind farm specific profitability analysis
system dependent optimizations
quality audits
The focus is on the optimization of the technology
Future orientated maintenance and engineering concept
Voith Industrial Services Wind | | 19
Erection, modernization & optimization of WTG´s
Exchange of big components: for example:
- gearboxes, rotor blades, generators, drive train / transmissions, hub, nacelle
Repowering of WTG`s
The key task consists of the coordination of resources (for example: cranes,
transportations, service technicians).
Project Management of complex projects
| | 20
Voith Service Plus New innovative Service Concepts
| | 21
For windfarms >25 MW
highly homogenous turbines
Safety due to longterm contracts
with calculated risk and chance
Efficient cost control due to „flatrate“
Optimization of personnel useage
Focussed training on fleet
fast response and defined processes
Optimization of spare part management
Reporting for adequate cost control
lean overhead structure
Availability guarantee
Innovative Service contracts: Voith Service Plus
Voith Industrial Services Wind | 20090408 | 22
„The Voith Service Plus can increase the income from existing parks“
Step 1:
Audit
Technical and economical total
check
Step 2:
New O&M Concept
Preventive Maintenance and Finance
planning. O&M optimized according to
down times and income.
Optimized Contracts.
Voith Industrial Services Wind | 20090408 | 23
Reference Site: with the Voith Service Plus the availability was increased by 5 % and the earnings by 6% ….
Zeitraum: Sept. 03 - Aug. 04 / Sept. 04 - Aug. 05 / Sept. 05 - Aug. 06
94,34%
96,73%
97,60%
90%
91%
92%
93%
94%
95%
96%
97%
98%
99%
100%
Sept. 03 - Aug. 04 Sept. 04 - Aug. 05 Sept. 05 - Aug. 06
Voith Industrial Services Wind | 20090408 | 24
Zeitraum: Sept. 03 - Aug. 04 / Sept. 04 - Aug. 05 / Sept. 05 - Aug 06
0 kWh
2.000.000 kWh
4.000.000 kWh
6.000.000 kWh
8.000.000 kWh
10.000.000 kWh
12.000.000 kWh
Ertrag 01.09.03 -
31.08.04
Ertrag 01.09.04 -
31.08.05
Ertrag 01.09.05 -
31.08.06
….i.e.: increase from power generation around 5 % reducing the non-producing periods by approx. 34 %...
Ausfälle in kWh
Voith Industrial Services Wind | 20090408 | 25
… with slight increment of the Service Costs taking into account the lack of repairs in the previous years
Zeitraum: Jan. 04 - Aug. 04 / Sep. 04 - Aug. 06
0 €
1.000 €
2.000 €
3.000 €
4.000 €
5.000 €
6.000 €
7.000 €
8.000 €
Servicekosten Wartungspauschale Gesamtsumme
Voith Industrial Services Wind | 20090408 | 26
… with slight increment of the Service Costs taking into account the lack of repairs in the previous years (incl. price increase of former OEM service provider
Zeitraum: Jan. 04 - Aug. 04 / Sep. 04 - Aug. 06
0 €
1.000 €
2.000 €
3.000 €
4.000 €
5.000 €
6.000 €
7.000 €
8.000 €
Servicekosten Wartungspauschale Gesamtsumme
Voith Industrial Services Wind | 20090408 | 27
… resulting in an better income by approx. 6%.
Zeitraum: Sept. 03 - Aug. 04 / Sept. 04 - Aug. 06
-20.000 €
-10.000 €
- €
10.000 €
20.000 €
30.000 €
40.000 €
50.000 €
60.000 €
70.000 €
80.000 €
Ertrag pro Monat Kosten pro Monat Bilanz
Voith Industrial Services Wind | 20090408 | 28
Co-operational activity concept and failure management
increase of site presence coordinating the planned visits for maintenance by the
Service Team and Inspections by the operator´s manager
quickest site presence at failures by the Operators and /or the Service
Common data levels and Interfaces
Development from aimed Reengineering Concepts supported by huge amounts of
Data.
Utilization of operational data allowing the Service to apply preventive Maintenance.
Partnership with separate Responsibility
Controlling function from Operator and Service with common objectives: best income
for the customer.
The ProfitGuard - a product resulting from a Partnership between Operator and Service Provider
Voith Industrial Services Wind | | 29
References Wind – Conergy Services Product cooperation: „Conergy Profit Guard“
professional judgement of WTG´s
down times reduction by analysis and action plans
preventive maintenance, which makes sure that the
profitability of the WTG´s increased
increase of availability of WTG´s
in comparison with the conventional operating
management & maintenance till 6% economies scale
with the Conergy ProfitGuard
Voith Industrial Services Wind | 20090408 | 30
References Wind – e.n.o. energy Grow jointly – erection & service of the WTG type „e.n.o. 82“
frame contract for the erection of the WTG type e.n.o.
82 in Germany (across Europe in negotiations)
frame contract for long-term maintenance of e.n.o. 82
in Germany (across Europe in negotiations)
troubleshooting service / remote monitoring (24/7)
object spare parts
converter services
general repairs
Voith Industrial Services Wind | | 31
References Wind – International Power frame contract for operation of different WTG types
a subsidiary company of International Power Plant
(international power generator; is considered to one
of the worldwide leading, independent power
generator)
Supervise volume for Levanto:
83 WTG (NM82 / V47 / GE1.5 / Bonus1300 / N60)
with an overall performance of 99 MW
Voith Industrial Services Wind | | 32
References Wind - Gamesa Eolica, Gamesa Wind Erection of wind energy turbines
Erection, as well as the completion for
commissioning of WTG´s of the type G52/G58 at
different locations in Germany
Commissioning of WTG´s of the type G80 in
Poland
documentation of the erection activities
Voith Industrial Services Wind | | 33
References Wind - Plambeck Erneuerbare Energien Optimization of different WTG types
planning of all on-site services, which are relevant
for the availability
disassembling & reaasembling of big components
coordination of the subcontractors:
- in the fields of cranes, transportations,
maintenance
pro-availability spare part management
reporting system for the insurer
improvement / optimization of critical prefabricated
parts (for example: slip ring motor)
Key-Account-Management:
regular information exchange with the operator &
the plant manager
Voith Industrial Services Wind | | 34
References Wind - EnerVest AG Wind farm redevelopment
wind farm (WF) redevelopment of the WF Staffelstein
8 x Südwind S70 (12 MW)
Installation of a wind farm network
Retrofit der Umrichter und Kupplungen
redevelopment of all pitch- & azimuthsystems, brakes
service for generators (incl. overhauling of the slip
ring motors) und gear boxes
upon completion long-term service & maintenance
contract
supervised volume for Enervest:
25 WTG (S70 / GE1.5 / NEG MICON NM60) with an
overall performance of 31 MW
Voith Industrial Services Wind | | 35
References Wind – e.disnatur Erneuerbare Energien Pilot project: Vestas
3 wind farms with 14 wind turbines of the type V80 and
V90
overall performance: 28 MW
location: Germany (Mecklenburg – Vorpommern and
Brandenburg)
Voith Industrial Services Wind | | 36
References Wind – FKI Engineering Ltd. First project abroad: Austria
11 wind turbines of the type D8 and 19 wind turbines of
the type D6 with an overall performance of 45,75 MW
First „Voith Service Plus“ – contract
this contract includes particularly:
- maintenance
- servicing flat rate
- availability warranty
- bonus-malus-agreement
- spare part flat rate and the availability warranty
of them
term of contract: 8 years
Voith Industrial Services Wind | | 37
Voith Industrial Services Wind | | 38
Your expectations
What does the customer expect from an independent service provider?
Full service from one source for WTG´s of all OEM´s
Economic safety of a strong partner
Experience & expertise
High technical availability by flexible spare part management and 24/7- remote
monitoring
Early detection of damage by latest WTG diagnostic
Maintenance / service contracts with long-term cost certainty
Transparency
Monteurstreffen VIWS 2010| 39
Monteurstreffen 2010 Produktmanagement: Aufgaben & Verantwortlichkeiten
technischer Support Monteure, DFÜ-Mitarbeiter und Projektleiter
herstellerbezogene Dokumentation
- Bereitstellung für alle VIWS Mitarbeiter
herstellerbezogene Upgrades und Optimierungen
- Mitwirkung aller VIWS Mitarbeiter
- Erläuterung der Vorteile und Wirkungen
herstellerbezogenen Arbeitsanweisungen und Wartungshandbüchern (bei Bedarf)
herstellerbezogene Schulungen und Unterweisungen von Monteuren, DFÜ-
Mitarbeitern und Projektleiter
- Vorbereitung von Hilfen zur Fehlersuche und Eingrenzung von sporadischen Fehlern
- Erläuterung spezifischer Probleme oder Zusammenhänge
Voith Industrial Services Wind | | 40
Attribution of the Product Managers to the OEM
Vestas/NEG Micon
Roman Müller
Mario Zengerling
(Team Thüringen I)
Siemens/AN Bonus
Thomas Kühnrich
Jan Linke
(Team Lübeck II)
MD70/77 Baureihe
Mario Bemerl
Peter Schüler
(Team Düren)
Nordex
Thomas Kellermann
Sven Gerke
(Team Karstädt)
DeWind
Andreas Bauer
Marko Nitschke
(Team Bremen)
Gamesa
Roman Müller
Avelion Fernández
(Team
Ludwigshafen)
GE / Enron / Tacke
Jens Monsees
Martin Lewinske
(Team Heide)
Voith Industrial Services Wind | | 41
In case of problems in the field, the following level of escalations are effective:
1st Level Support First contact person in case of occured
problems is the remote monitoring or
the responsible project manager for the
wind farm if the problem can not solve in the 1st
level: forwarding the problem to the 2nd
level
if the problem can not solve in the 2nd
level: forwarding the problem to the 3rd
level
team give notice of a problem
2nd Level Support
3rd Level Support
contact person, if the problem can not
solve in the 1st level are the product
manager
contact person, if the problem can not
solve in the 2nd Level is the technical
department