Leergang offshore wind Uitdagingen in de logistiek Prof.dr. Ruud - PowerPoint PPT Presentation

faculteit economie vakgroep operations 14-11-2019 | 1 en bedrijfskunde | 14-11-2019 1 Leergang offshore wind Uitdagingen in de logistiek Prof.dr. Ruud Teunter Dr. Jasper Veldman

14-11-2019 | 2 Offshore logistics network

14-11-2019 | 3 Port facilities

14-11-2019 | 4 Spare parts  Infield cables  Export cables  Turbine blades  Turbine components  Spare turbines

14-11-2019 | 5 Transport

14-11-2019 | 6 Transport

14-11-2019 | 7 The main players in O&M (S)LSP = (specialist) logistics service providers, OWF = offshore wind farm, OEM = original equipment manufacturer IMSP = independent maintenance service provider

14-11-2019 | 8 Some basic principles › A service provider uses a mix of maintenance policies:  Corrective (run-to-failure)  Calendar-based  Condition-based › Different jobs, different turbine components, different vessels › Importance of weather restrictions

14-11-2019 | 9 Offshore wind – O&M overview Offshore wind process Installation Logistics Maintenance • Turbine layout design • Fleet size and mix • Spares supplier selection Strategic • Wind park dimensioning • Warehouse location • Contracts definition horizon level Planning Tactical Human resource capacity planning • Master distribution plan • Environment forecasting • Spare parts inventory policies • Maintenance policy optimization • Vehicle routing • Scheduling maintenance tasks Operational • Spare part distribution and collection • Routing technicians Our focus

14-11-2019 | 10 TACTICAL MAINTENANCE JACK-UP VESSEL DEPLOYMENT

14-11-2019 | 11 The setting › Jack-ups needed for large component replacements (e.g., blades) › Short term chartering costs are immense › Logistics-related delays drastically raise costs

14-11-2019 | 12 Cooperation options

14-11-2019 | 13 Vessel sharing

14-11-2019 | 14 Vessel sharing

14-11-2019 | 15 TACTICAL LOGISTICS SPARE PARTS MANAGEMENT (ON AN SOV)

14-11-2019 | 16 Service Operations Vessel https://www.youtube.com/watch?reload=9&v=lk_ww_ynWh4

14-11-2019 | 17 Characteristics Service Operations Vessel Offshore for 2 to 3 weeks • Can host tens of workers • Small repair shop • Small crane • Electronic gangway system • Helicopter deck • Carries spare parts or • subassemblies for - Hydraulics - Generator - Gearbox - Electric system

14-11-2019 | 18 What to bring offshore? SOV Kit › Goal: find (nearly) optimal SOV stock › Determine the probability that (the n-th) part of some type is needed on a tour › Calculate the ratio of that probability and the cost price of a part › Rank parts based on the ratio (high to low) and add parts to the stock in this order › Easily done in Excel

14-11-2019 | 19 TACTICAL MAINTENANCE (AND PRODUCTION) GET VESSELS, PARTS, TOOLS AND TECHNICIANS READY

14-11-2019 | 20 Smart supply chain Internet of Things (IoT)

14-11-2019 | 21 Wind turbine sensoring

14-11-2019 | 22 Condition-based maintenance Condition monitoring › Condition data (Big data) › Condition information (analytics, data mining) › Condition-based maintenance

14-11-2019 | 23 Condition-based production › Maintenance planning lead time Condition monitoring › Control of the production rate Weather Technicians lead time Spare parts Tools

14-11-2019 | 24 Smart production & SC › Variable production speed › Higher production speed leads to more vibration and higher temperatures › Trade-off: production versus deterioration

14-11-2019 | 25 Smart production & SC A block diagram of a wind turbine system (ABB, 2011)

14-11-2019 | 26 The single turbine case Decelerate Decrease risk of failure Accelerate Increase production

14-11-2019 | 27 Win-win scenario › Lower maintenance cost and lower production losses Cost reduction 10% -- 20% extra production

Two turbines (high maintenance 14-11-2019 | 28 setup costs) › Better to maintain both wind turbines at the same time › Set higher production rate for less deteriorated turbine Condition-based production rates Constant, equal production rates Deterioration processes of turbines are much better synchronized

14-11-2019 | 29 OPERATIONAL MAINTENANCE SCHEDULING TASKS GIVEN VESSELS, PARTS, TOOLS AND TECHNICIANS

14-11-2019 | 30 Scheduling inputs › Maintenance tasks Service time, number of technicians, type of technicians, spare  parts (kg) › Availability of technicians in the harbor › Fleet Capacity for personel, spare parts, speed, costs, heterogenous  › Weather conditions How long can a particular vessel type work during a period  › Set of periods available for scheduling tasks Technicians Fleet Maintenance tasks Repair or inspection?

14-11-2019 | 31 Scheduling algorithm Minimize total costs: › Fuel/transportation costs › Technician costs (cost per day) › Maintenance costs Balancing act between 1) Vessel moves with technicians (fewer technicians needed) 2) Vessel picks up and delivers technicans between turbines (fewer vessel trips and lower fuel costs)

14-11-2019 | 32 Scheduling outcomes Technicians Fleet Maintenance tasks Repair or inspection? Transportation (fuel) costs Scheduling algorithm Technician costs Maintenance costs Plan technicians Plan tasks Select and route vessels Benefits: • Efficiency, cost reduction • Reduced mean time to maintenance • Better use of technicians • Fewer vessel trips

14-11-2019 | 33 COMBINED INSIGHTS: SIMULATION TOOL

14-11-2019 | 34 Simulation tool modules To be developed in AnyLogic Simulation Software Turbine Model Weather Model Maintenance Logistics Dashboard 1 2 3 4 5 • Wind speeds • Vehicle routing • Performance measures • Deterioration process • Maintenance policies • Temperature • Inventory management • Planning suggestions • Power generation • Preventive maintenance • Technician scheduling • Excel reports • Service demands • Rain • Corrective maintenance • State inspection • Wave heights • Repair kit problems Purely simulation Simulation and optimization Analytics and data visualization

14-11-2019 | 35 Screenshots

14-11-2019 | 36 STRATEGIC MAINTENANCE CONTRACTING

14-11-2019 | 37 Contracting & collaboration OEM Service Owner Provider

14-11-2019 | 38 Maintenance contract? › Wind turbines are often sold with two or five years of warranty › Question: › Should the buyer/owner of wind turbines directly sign a long-term maintenance contract with the OEM (bundling) or not (un-bundling)? OEM i bundling 20 yrs OEM i or OEM j OEM i unbundling auction auction

14-11-2019 | 39 Critical tradeoffs › Two features of the maintenance industry:  OEM's learning-by-doing: maintenance cost decreases over time  Competitive market: more independent service providers than OEMs › Trade-off owner: A long term contract  always takes advantage of the OEM's learning-by-doing and motivates the OEM to invest in turbine reliability, but  foregoes the chance to choose a more efficient provider

14-11-2019 | 41 Some findings Bundling Unbundling (1 contract) (2 contracts) Making a mess for others Investment in turbine reliability Learning-by-doing  turbine reliability Owner’s cost Few service providers Strong learning Owner’s cost Many service providers Weak learning

14-11-2019 | 42 BEYOND OFFSHORE WIND

14-11-2019 | 43 Smart Grids in City Areas http://smarthome.lisha.ufsc.br/index.php/Main_Page

14-11-2019 | 44 Energy storage: balancing smart grids http://www.powermatchingcity.nl

14-11-2019 | 45 Energy storage management › Integration with renewable resources such as wind and solar power › Integration with natural gas grid › Buffer to balance fluctuating consumption and generation

14-11-2019 | 46 Research questions › How to deploy and control energy storage units to improve system performance?  Where to install the conversion and storage units?  How to dimension these units?  What is the optimal control policy?

14-11-2019 | 47 Questions?