IDENTIFICATION OF CRITICAL OPERATION CONDITIONS & DETERMINATION OF THE NEXT OIL EXCHANGE

Transcription

1 CONDITION BASED MAINTENANCE OF OFFSHORE WIND TURBINES BY 24 / 7 MONITORING OF OIL QUALITY, OIL AGING AND ADDITIVE CONSUMPTION: IDENTIFICATION OF CRITICAL OPERATION CONDITIONS & DETERMINATION OF THE NEXT OIL EXCHANGE 1 Dr.-Ing. Manfred R. Mauntz Dr. rer. nat. Jörn Peuser

2 Contents Introduction - Existing measurement techniques Innovative measurement principle WearSens How WearSens identifies critical operation conditions of wind turbines? Results of a wind turbine field installation 2

3 Machine condition Existing techniques Existing techniques start working after particle formation, after damage is done Standard solutions provide information after damage occurred. Start of damage Particle- Measurement Vibration sensor Sound No detection! Temperature Smoke emission time Minutes Days Weeks 3

4 Conductivity Comparison: Optical particle counter and WearSens Tribological layer gets depleted! Pump ps/m Particle counter detects damage! Source ions ions No detection! Oil reservoir particlecounter Detector 4

5 Conductivity Comparison: Optical particle counter and WearSens Tribological layer gets depleted! Pump ps/m Particle counter REDUCED DETECTION! Source ions Magnet ions LOW DETECTION! Magnetic field lines S N particlecounter Detector 5

6 Machine condition WearSens The presented sensor system enables a continuous monitoring already from the first day, providing comparative data. Optimizing load Indicating service Predicting damage continuous Oil condition monitoring Advanced warning time Particle- Measurement Start of damage Vibration sensor Sound Temperature due to direct feedback and optimized load regulation. Development and optimization of new gearboxes / components Smoke emission by extended test stands analysis. time Minutes Days Weeks 6

7 Measurement principle The WearSens unit measures three components: Specific electrical conductivity k 7 Relative permittivity e r Temperature T the values k and e r are determined independently. Identification of the additive consumption by e r Self learning, adaptive temperature compensation of k and e r

8 How WearSens identifies critical operation conditions of wind turbines? WearSens Index WS i 8

9 Power [a.u.] Condition Based Maintenance with WearSens - Monitoring of oil aging Short and long-term changes in the lubricant are considered in the model. The stress of the lubricant is based on the actual wind conditions/fluctuations and wind turbine settings resulting in changes of the conductivity and relative permittivity. Frequent critical operation conditions lead to faster degradation of the Oil-Additive-Complex. WS i : WearSens Index Planned maintenance Condition Based Maintenance Time window oil exchange Planned maintenance Ws i Time t [year] 9

10 Offshore oil change with SWOC 1.0 Container system - SWOC 1.0 fully offshore certified - pre-heated oil for short pump times - Flushing oil for optimal gearbox cleaning Source: 10

11 Field installation results of a wind turbine Data 11/2015 Comparison of Vibration monitoring and WearSens 11

12 Comparison vibration monitoring competitive CMS CMS Vibration 12

13 Comparison vibration monitoring competitive CMS with cmc CMS WS i cmc CMS Competitor Early detection of events Even at a low time resolution setting, the important peaks are clearly visible! Later response Low time resolution Time (h) 13

14 Comparison vibration monitoring competitive CMS with cmc CMS WS i cmc CMS Competitor Early detection of events At maximum time resolution: Full control with high information density Later response Low time resolution Time (h) 14

15 Condition Based Maintenance with WearSens - Monitoring of oil aging PMM CBMS Maintenance PROTECTION & SAVINGS Zeit [Jahre] 15

16 Server-Interface via Internet Browser REMOTE ACCESS 24 / 7 Automatic notification 16

17 Benefits of the combination of Condition Based Maintenance & Online Monitoring Extended oil change interval Reduced costs Preserve the environment Resource protection Real-time information about the current oil status Online Monitoring Detection of critical operation conditions Prevent damage and increase life time Prevent expensive downtimes and additional maintenance costs 17

18 Questions? Dr.-Ing. Manfred R. Mauntz cmc Instruments GmbH Hauptstrasse Eschborn / Germany Phone MRM@cmc-instruments.de 18

19 Contact: Dr.-Ing. Manfred Mauntz cmc Instruments GmbH Hauptstraße Eschborn