CMS. Condition Monitoring System. More Safety, Greater Yield

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1 CMS Condition Monitoring System More Safety, Greater Yield

2 Round the Clock One System, One Partnership With over 60,000 installed systems, Bachmann electronic is the clear Number 1 in the automation of wind energy plants. In other areas of renewable energy, in shipbuilding and in special machine building as well, renowned customers worldwide are placing their trust in our specific know-how and our tremendous innovative capacity. We develop and produce for them innovative control, communication and visualization systems, as well as condition monitoring solutions, which have the one central aim: Keeping the total cost of ownership of a plant as low as possible. 365 days a year. Content 4 THE VALUE ADDITION IN WIND ENERGY Complete solutions from Bachmann electronic 6 CONDITION MONITORING More than just vibration measurement an overview 10 PLANNED COST REDUCTION Condition monitoring increases the yield of your wind turbine 2

3 BACHMANN ELECTRONIC LEADERS IN WIND POWER With over 40 years of experience as automation specialists, including over ten years in the wind power sector, and with around 500 employees and branches all over the world, Bachmann electronic is today the leading supplier in the automation of wind turbines. With its own Monitoring Center, the company also monitors to date over 1,700 wind energy plants worldwide. 14 EFFICIENT ANALYSIS Powerful software supports the plant manager 16 POWERFUL OVERALL CONCEPT Plant monitoring as a service 18 MODULAR SYSTEM Product portfolio for condition monitoring 3

4 The Value Addition in Wind Energy Our solutions for energy grid management combine control, communication, monitoring and visualization seamlessly into a comprehensive whole. Bachmann automation solutions thus give you the critical value addition. Critical for your success and critical for the energy supply of tomorrow. Nacelle ONLINE MONITORING At Bachmann, condition monitoring is deeply integrated in the automation, thus enabling you to implement optimized conditioning monitoring for your wind turbine in terms of cost and functionality. Trained experts in our Monitoring Center continuously watch over the condition of your plant on request. Diagnostics/ teleservice HIGH PRECISION SENSORS Specially designed sensors from Bachmann supply the measuring data for meaningful oscillation, shock and vibration analysis. OPTIMIZED COMMUNICATION bluecom is the communication protocol developed by Bachmann for fast and secure information exchange in smart grids. bluecom IEC (MMS) OPC Tower Box 4

5 Our solutions have one aim: Keeping the total cost of ownership of your plant as low as possible. SECURED PRODUCTIVITY Pitch The Bachmann M1 automation system has a proven availability of over 99.96%. With the integrated safety and redundancy solutions you can ensure the virtually failsafe operation of your plant. A MATCH FOR ANY CLIMATE The coldclimate modules from Bachmann are the ultimate answer to extreme climatic conditions. They can withstand extreme temperatures from -40 C to +70 C even when condensation is present. Grid Measurement and Protection INTEGRATED GRID MANAGEMENT Bachmann integrates grid measurement and synchronization in the conventional control tasks of your power generation plant. The monitoring and protection functions enable safe and grid compliant operation. 5

6 Condition Monitoring More than just vibration measurement an overview Wind turbines are production units. Their availability has a direct effect on their amortization and the supply of energy to the grid that can be planned reliably. Condition monitoring systems (CMS) thus provide the operator with continuous information about the operating state of the turbine. This makes it possible to predict any impending mechanical or electrical damage to the wind turbine in advance during operation. Downtimes for repair and maintenance can be planned and prepared systematically, plants can be kept longer on the grid, and consequential damage prevented. Condition monitoring involves the monitoring of the status of a machine either continuously or at regular intervals through the measuring or analysis of meaningful physical variables (e.g. vibrations, temperatures, condition of lubricant etc.). The comparison with the reference measurements provides information for drawing conclusions about the actual condition of gears, generators, roller bearings, rotors and other components. 6

7 CERTIFIED CONDITION MONITORING The requirements of Germanischer Lloyd for the certification of condition monitoring systems in wind turbines stipulates that at least the main bearings, main gears, generator and nacelle including the tower should be covered by condition monitoring. In order to monitor main bearings, main gears and generator, at least six acceleration sensors with a frequency range of 0.1 Hz 10 khz, and for the nacelle and tower one acceleration sensor each in the axial direction (wind direction), as well at right angles to it with a frequency range of 0.1 Hz 100 Hz are required. 7

8 Perspective: Systematic yield optimization A condition monitoring system considerably reduces the risk of failure and maintenance costs of a wind turbine plant. It also provides options for increasing the profitability of your plant. By combining the information from the automation system, the currently prevailing environmental conditions such as wind speed or ambient temperature, and by evaluating the load measurements of relevant components, any reserves available to the plant can be identified. This enables the plant manager to further exploit the potential of the wind turbine and run it at optimum yield. MAINTENANCE ONLY IF NEEDED Condition monitoring enables conditionbased maintenance. The generally practiced preventative maintenance involving the exchange of components within fixed time intervals based on empirical values is replaced by a condition-based maintenance strategy. This provides you with a clear financial benefit. 8

9 BENEFIT: INTEGRATED CMS SOLUTION Bachmann integrates its condition monitoring solution in the automation and links the measured values to other operating parameters. This increases the diagnostic reliability of the condition monitoring: Fault patterns can be compared to the current operating situation and interpreted with greater accuracy. A systematic control even enables mechanical loads to be reduced. In this way, adjusted operating conditions can extend the lifespan of partly damaged parts up to the next plannable maintenance date. CERTIFIED SAFETY All the system components used for condition monitoring including the online remote Monitoring Center are certified in accordance with the regulations of Germanischer Lloyd. Bachmann automation components are furthermore provided with several internationally recognized approvals for use in wind energy plants and offshore applications. 9

10 CONDITION MONITORING The condition monitoring of a wind turbine supports the technical plant manager in controlling the maintenance intervals and in setting priorities systematically. This enables the optimum planning of maintenance schedules, personnel and materials, taking seasonal conditions into account. In the medium-term, the results also help to improve maintenance strategies and forecast the expected operating costs of a plant more clearly. 10

11 Planned Cost Reduction Condition monitoring increases the yield of your wind turbine The maintenance and operating costs of a wind turbine depend on the costs for service and maintenance work, the costs for spare parts, and the cost for logistics (transport and installation equipment such as cranes). However, the loss of yield caused by the downtime must also be included in the calculation. Both aspects must be kept to a minimum. ONLINE CONDITION MONITORING PAYS FOR ITSELF The replacement of a bearing on the gear shaft requires a planned downtime of the wind turbine of around three to four days. In the case of a sudden break caused by wear damage that was not detected in time, this time can easily be ten times longer since material and personnel first have to be organized and brought to the plant. Sudden breaks are also often due to higher wind loads in times of strong wind and therefore high yields. If the sudden break causes consequential damage to components, which can only be partially repaired on the plant due to their size and dimensions, additional expenditure is involved. The costs for the use of a crane, particularly with offshore installations are enormous. LOSS OF REVENUES in thousand Euros Planned maintenance Downtime: 2 weeks low wind period Sudden failure Downtime: 10 weeks Planned maintenance Downtime: 2 weeks strong wind period Sudden failure Downtime: 10 weeks Taking only the loss in yield into account, the repair after a sudden failure in times of weak winds can result in an additional loss of approx. 20,000 euros and well over 40,000 euros in times of high wind. (comparison of a planned and unplanned repair of gears on a 1.5 MW turbine; at times of weak wind and at times of high wind.) 11

12 Yield optimized maintenance planning In most regions of the world, wind speed depends on the seasons. Directly linked with this is the potential yield of a wind turbine plant: Around two thirds of the electricity yields mostly occur in the months from November to April. Plant failure must therefore be avoided in these months at all costs. In addition to this is the fact that logistical costs for maintenance in the winter months are normally higher. Condition monitoring supplies the facts required to plan maintenance so that the energy availability of the plants is hardly affected. PREVENTING CONSEQUENTIAL DAMAGE Condition monitoring provides reliable information about the state of important mechanical and electrical components of the wind turbine. This enables any faults to be detected early as well as preventing any possible consequential damage that would mean a lengthy downtime of the installation. RISIKOABSICHERUNG RISK PROTECTION Condition Condition monitoring Monitoring gives operators, liefert Betreibern, investors and insurers Investoren a practical und and Versicherern transparent ein view praxis- of the condition nahes, of the transparentes plant and Bild thus des also Anlagenzustands risk of loss. und This damit is particularly auch eines important zu er- when commissioning wartenden Schadenrisikos. or at the end of Dies the ist warranty von period when besonderem service contracts Interesse and bei insurance der Inbetrieb- premiums nahme have to oder be auch recalculated. zum Ende der Gewährleistungsfrist, wenn Serviceverträge und Versicherungsprämien neu kalkuliert of the expected werden. 12

13 BENEFITS OF CMS AT A GLANCE Reduction in maintenance costs through coordinated planning, timely procurement of spare parts and prevention of consequential damage Securing of electricity generation and yield optimization through selective and planned maintenance, e.g. in times of weak wind Greater utilization of the lifespan of machine elements thanks to accurate condition information Practical risk assessment in relation to the failure of important wind turbine components REVENUES in thousand Euros % 8% 9.5% 7% 7% 5.5% 8.5% 4% 7% 4% 9.5% 11% Around two thirds of the yields of a wind turbine are generated in the winter months when high winds are more frequent. (Sample calculation for a 1.5 MW wind turbine plant) months 13

14 Efficient Analysis Powerful software supports the plant manager WebLog is the web-based front end of the Bachmann Condition Monitoring System. It functions as the communication interface to the diagnostics system and enables the secure and mobile access to the condition data of the wind turbine. TRAFFIC LIGHT SYSTEM If predefined limit values are exceeded, WebLog initiates an alarm message which is indicated to the user in a status window, and which can be sent by or SMS. Extensive tools for signal analysis, such as envelope spectrums, amplitude spectrums, or frequency-based characteristic values support the diagnostics specialist in detecting and interpreting changes in the characteristic healthy picture of the monitored components. INTEGRATED TREND ANALYSIS An integrated database enables the trend analysis of the data recorded from individual machine components and units over a longer time period. AUDIBLE VIBRATION SIGNATURE As well as convenient and clear visualization, WebLog also provides the possibility to make sensor signals audible. In this way, irregularities in the measured spectrum can be assessed acoustically, which very often allows an actual fault to be identified quickly. 14

15 The Bachmann Online CMS Ω-Guard provides worldwide access to the status data of the monitored plant from any online workstation. Ω-Guard System Commissioning and configuration Sensors WebLog workstation Internet et Condition monitoring system WebLog server WebLog workstation WebLog workstation Remote plant management 15

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17 Powerful Overall Concept Plant monitoring as a service The result of online condition monitoring largely depends on the proper installation, parameterization and commissioning of the CMS system, as well as on the fast and correct response to reported status changes. ONLINE CONDITION MONITORING Wind turbines are complex systems that are continuously exposed to changing operating conditions. The modular Bachmann Condition Monitoring System is therefore adapted individually to the special characteristics of the turbine type and parameterized accordingly. The data of all monitored plants is consolidated in the Bachmann Monitoring Center and analyzed by experienced diagnostics specialists. The bringing together of the characteristic data from condition monitoring and the operating parameters of the automation system enables changes to measured values to be explained often in advance and faults prevented. Depending on the service agreed, the plant manager not only receives a verified fault message, but also an assessment of the operational relevance and concrete action recommendations. MOBILE MEASUREMENTS (OFFLINE) Mobile measurements in the field are also possible for example, as part of the installation acceptance or routinely at the end of the warranty period. For this we will install the required sensors on your wind turbine for an agreed period in order to monitor selected characteristic values. Experienced analyzers prepare the measured data and supply you with a meaningful status report on the condition of the monitored components. ADVISORY SUPPORT Worldwide access to plant data is possible thanks to the web-based communication to the Bachmann Condition Monitoring System. In this way Bachmann can provide advisory support to operators with their own monitoring center at any time. 17

18 Modular System Product portfolio for condition monitoring Condition monitoring systems not only place the most demanding requirements on sensors and data acquisition, but also on the processing and routing of the data. Our powerful and internationally approved hardware and software components form the basis for reliable statements to be made about the condition of a machine. CONDITION MONITORING SYSTEM Ω-GUARD Analog inputs Number 9 3 Ω-Guard : Completely integrated solution. Ω-Guard : Stand-alone system. Measuring range AC-coupled ±6 V ±10 V IEPE interface Resolution > 17-bit Dynamics > 95 db Frequency range, general 0.1 Hz 20 khz Incremental and counter inputs Interface 24 V initiators / proximity switch with 10 ma sink incremental can be used either as an incremental interface or as two counter inputs for proximity switches Number of channels 2 1 Counter frequency 5 khz 36 khz Measured value / resolution 32-bit 32-bit Input signals A A-, A+ / B-, B+ / N-, N+ Evaluation - 1, 2, 4 edges & pulse direction mode Power supply For external sensors: 24 V / 5 V short-circuit-proof Galvanic isolation 500 V The tested and certified Ω-Guard Condition Monitoring System enables the permanent evaluation and storage of the measured data, as well as its automatic transfer in the CMS. Ω-Guard is specially designed for use in harsh environmental conditions and is suitable for both onshore and offshore wind turbines. The system is both fully integrated in the M1 automation system and is also available as a stand-alone solution. 18

19 SENSOR BAM100 BAM500 Sensitivity 100 mv/g 500 mv/g Output ICP compatible Measuring range 0.1/0.2-30,000 Hz Sensor connection M12 SENSOR μ-bridge Sensitivity Output Measuring range Sensor connection 0,7 V/N ICP compatible ,000 Hz M8 Our sensors are specially designed for safe signal acquisition, even with very slow running roller bearings, such as the main bearings or rotor bearings on the drive train of a wind turbine. STRUCTURAL VIBRATION MONITOR SVM300 Acceleration axes 2 (x, y), z optional Resolution 0.5 mg Max. acceleration ± 2 g Signal band width 5 Hz Sample rate min. 25 samples/s Data memory up to 150 days The SVM300 measuring module with protection to IP67 is used for analyzing oscillation, shock and vibration. It comes with an internal memory that enables stand-alone logging independently of the grid for up to 150 days. 19

20 Austria Corporate Headquarters Bachmann electronic GmbH Kreuzäckerweg Feldkirch, Austria P +43 (0) / info@bachmann.info Germany Bachmann Monitoring GmbH Weimarische Straße Rudolstadt, Germany P +49 (0) / office.rudolstadt@bachmann.info Bachmann electronic GmbH Egermannstraße Rheinbach / Bonn, Germany P +49 (0) / office.bonn@bachmann.info Denmark Bachmann Office Silkeborg Bachmann electronic Danmark Vejlsøvej Silkeborg, Denmark P office.silkeborg@bachmann.info USA Bachmann electronic Corp North Route. 45, Suite 203 Grayslake, IL 60030, USA P / office.chicago@bachmann.info China Headquarters China Bachmann electronic Technical Services (Shanghai) Co., Ltd. East Ocean Center Room 14C, Phase Yan an East Road Huangpu District, Shanghai, PR China P +86 (0) office.shanghai@bachmann.info Benelux Bachmann Office Veenendaal Bachmann electronic Nederland Vendelier PD Veenendaal, Netherlands P +31 (0) 85 / office.veenendaal@bachmann.info India Bachmann Office Pune Bachmann electronic Industrial Automation Private Limited, Pune 1/E, Classic Building, North Avenue Kalyani Nagar Pune , India P +91 (0) office.pune@bachmann.info Bachmann North America Bachmann Europe HQ Bachmann India Bachmann China Condition Monitoring broschure EN PB-CMS/02EN 05/2012 Subject to alterations without notice by Bachmann.