Voith Industrial Services Wind GmbH

dkvind.dk

Voith Industrial Services Wind GmbH

Voith Industrial Services Wind

GmbH

Presentation vindmøller i udland

Fredericia 14.10.10


Sales € in million

Profit from Operations € 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 | 2


Sales € in million

Sales

Voith Turbo

24%

34%

Voith Paper

Profit from Operations € in million

Voith Hydro

22%

20%

Voith Industrial Services

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 | 3


Voith is innovative

Voith – Where smart people like to

work

• 11,000 active patents

• 400 new patents every year

Voith Industrial Services Wind | 20090408 | 4


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 | | 5


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)

Voith Industrial Services Wind | | 6


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

Vestas / NEG

Micon

25%

(18%)

GE / Tacke

9%

(16%)

VIWS - Übersicht Bestandsanlagen

(Stand: 31.07.2010)

Gamesa

3%

(0%)

Siemens

4%

(4%)

DeWind

24%

(20%)

Nordex

35%

(42%)

Beirat VIWS |Hamburg 2010-08-06 | 7


till 1 MW

till 1,5 MW

till 2,5 MW

WTG portfolio of more than 30 different types:

GE Wind Vestas / Gamesa Siemens Nordex

DeWind

Tacke TW 600

Tacke TW 600e

M 1500/1800

NM 48 / NM 52

NM 60

V 39/ V 47/ V 52

AN Bonus 450 KW

AN Bonus 600 KW

AN Bonus 1 MW

Nordex N 27/29

Nordex N 43

Nordex N 50

Nordex N 52/54

DeWind D4

DeWind D6

(1 MW)

GE 1,5 Series

(incl. Tacke &

ENRON)

NM 64c

NM 72c

NM 82

AN Bonus 1,3 MW

Nordex N 60/62

Südwind S 70/77

(incl. MD 70/77)

DeWind D6

(1,25 MW)

GE 2.X Series

V 80/ V82

(incl. Gamesa G80)

AN Bonus 2,3 MW

Nordex N 80/ 90

2.500 kW

DeWind D8

DeWind D8.2

(2 MW)

Voith Industrial Services Wind | | 8


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

Voith Industrial Services Wind | | 9


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| 10


Quality management

Product management: Escalation processes

Team reports

Problem

Nordex

Thomas Kellermann

Sven Gerke

(Team Karstädt)

MD70/77 Baureihe

Mario Bemerl

Peter Schüler

(Team Düren)

Vestas/NEG Micon

Roman Müller

Mario Zengerling

(Team Thüringen I)

DeWind

Andreas Bauer

Marko Nitschke

(Team Bremen)

1st Level Support

„Product manager/

Technician“

2nd Level Support

Siemens/AN Bonus

Thomas Kühnrich

Jan Linke

(Team Lübeck II)

Gamesa

Roman Müller

Avelion Fernández

(Team

Ludwigshafen)

GE / Enron / Tacke

Jens Monsees

Martin Lewinske

(Team Heide)

„Productmanager

Project leader“

3rd Level Support

Engineering

Monteurstreffen VIWS 2010| 11


Product management: Why

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

Konsequenz: je Technologie ein verantwortliches Team

aus Projektleiter und Monteur

Monteurstreffen VIWS 2010| 12


Quality management

Modular training concept

Monteurstreffen VIWS 2010| 13


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 | | 14


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 | | 15


Maintenance Management

WIS - Database

• acquisition of customer personal data

• acquisition of the supervised wind farms

• acquisition of the failures

• daily planning of the serviceteams

• three times a day: verification of the WTG´s

Voith Industrial Services Wind | | 16


Flexible logistics concept:

guarantee of availability for critical spare parts

Voith Industrial Services Wind | | 17


Future orientated maintenance and engineering

concept

The focus is on the optimization of the technology

• 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

Voith Industrial Services Wind | | 18


Project Management

of complex projects

The key task consists of the coordination of resources (for example: cranes,

transportations, service technicians).

• 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

Voith Industrial Services Wind | | 19


Voith Service Plus

New innovative Service Concepts

| | 20


Innovative Service contracts: Voith Service Plus












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

| | 21


„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 | 22


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

100%

99%

98%

97%

96%

96,73%

97,60%

95%

94%

94,34%

93%

92%

91%

90%

Sept. 03 - Aug. 04 Sept. 04 - Aug. 05 Sept. 05 - Aug. 06

Voith Industrial Services Wind | 20090408 | 23


….i.e.: increase from power generation around 5 %

reducing the non-producing periods by approx. 34 %...

Zeitraum: Sept. 03 - Aug. 04 / Sept. 04 - Aug. 05 / Sept. 05 - Aug 06

12.000.000 kWh

Ausfälle in kWh

10.000.000 kWh

8.000.000 kWh

6.000.000 kWh

4.000.000 kWh

2.000.000 kWh

0 kWh

Ertrag 01.09.03 -

31.08.04

Ertrag 01.09.04 -

31.08.05

Ertrag 01.09.05 -

31.08.06

Voith Industrial Services Wind | 20090408 | 24


… with slight increment of the Service Costs taking into

account the lack of repairs in the previous years

8.000 €

7.000 €

6.000 €

5.000 €

4.000 €

3.000 €

2.000 €

1.000 €

Zeitraum: Jan. 04 - Aug. 04 / Sep. 04 - Aug. 06

0 €

Servicekosten Wartungspauschale Gesamtsumme

Voith Industrial Services Wind | 20090408 | 25


… 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

8.000 €

7.000 €

6.000 €

5.000 €

4.000 €

3.000 €

2.000 €

1.000 €

Zeitraum: Jan. 04 - Aug. 04 / Sep. 04 - Aug. 06

0 €

Servicekosten Wartungspauschale Gesamtsumme

Voith Industrial Services Wind | 20090408 | 26


… resulting in an better income by approx. 6%.

Zeitraum: Sept. 03 - Aug. 04 / Sept. 04 - Aug. 06

80.000 €

70.000 €

60.000 €

50.000 €

40.000 €

30.000 €

20.000 €

10.000 €

- €

-10.000 €

-20.000 €

Ertrag pro Monat Kosten pro Monat Bilanz

Voith Industrial Services Wind | 20090408 | 27


The ProfitGuard - a product resulting from a Partnership

between Operator and Service Provider

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.

Voith Industrial Services Wind | 20090408 | 28


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 | | 29


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 | 20090408 | 30


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 | | 31


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 | | 32


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 | | 33


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 | | 34


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 | | 35


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 | | 36


Voith Industrial Services Wind | | 37


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

Voith Industrial Services Wind | | 38


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

Monteurstreffen VIWS 2010| 39


Attribution of the Product Managers to the OEM

Nordex

Thomas Kellermann

Sven Gerke

(Team Karstädt)

MD70/77 Baureihe

Mario Bemerl

Peter Schüler

(Team Düren)

Vestas/NEG Micon

Roman Müller

Mario Zengerling

(Team Thüringen I)

DeWind

Andreas Bauer

Marko Nitschke

(Team Bremen)

Siemens/AN Bonus

Thomas Kühnrich

Jan Linke

(Team Lübeck II)

Gamesa

Roman Müller

Avelion Fernández

(Team

Ludwigshafen)

GE / Enron / Tacke

Jens Monsees

Martin Lewinske

(Team Heide)

Voith Industrial Services Wind | | 40


In case of problems in the field, the following level of

escalations are effective:

team give notice of a problem

1st Level Support

2nd Level Support

3rd Level Support

First contact person in case of occured

problems is the remote monitoring or

the responsible project manager for the

wind farm

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

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

Voith Industrial Services Wind | | 41

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