SERVICES. Our maintenance and optimisation modules. Multibrand from Vestas to Gamesa to GE. Wind Systems A/S company

Transcription

1 SERVICES Our maintenance and optimisation modules. Multibrand from Vestas to Gamesa to GE. A Wind Systems A/S company

2 Recommended by our engineers: FC Remote Access: So close and yet so far away. Remote monitoring can often correct faults without a service team needing to be deployed. However, until now frequency converter (FC) malfunctions have almost always necessitated on-site repairs. With our FC Remote Access, the FC can also be accessed remotely and malfunctions quickly analyzed and efficiently corrected. Internal crane system: tackles the toughest of tasks with the greatest of ease. Available for Vestas WTGs in types V66, V and V The use of heavy-duty cranes entails a great deal of work and high costs. The internal crane system from Availon is an alternative. Weighing just 200 kg makes it quick and flexible to use for replacing generators or transformers without long waits even at high wind speeds. LED obstruction lights: a shining light for the long term. LEDs are virtually unbeatable with regard to efficiency and reliability. Compared with conventional obstruction lights, they also prevent costly lightbulb replacements and the exchange of sensitive devices in WTGs. Our LED obstruction lights are maintenanceand wear-free and meet all the legal requirements. Line reactor ventilation system: Temperature-oriented to a high degree. We discovered heat accumulation in the vicinity of the line reactor in some WTGs, which prevented adequate cooling. This reduced the service life of the line reactor and promoted short circuits with serious consequences. The solution: The temperature-sensitive line reactor is protected by means of high-performance diagonal fans. Control box for Vestas WTG: Full facilities to go. Instead of operating the turbine from the tower base, the control box can be used to access the controller of the WTG directly from the nacelle. This takes place via a portable control panel, e.g., in order to activate the rotor lock before work is carried out in the hub. This speeds up the work, thereby saving time and money. Access monitoring: Good ideas to prevent unpleasant surprises. Besides the material damage, break-ins into WTGs also cause massive repair costs, since the culprits usually use brute force. The solution: The solution: our access monitoring system, which monitors the area in front of and inside the WTG with motion detectors and acoustic sensors. If in doubt, remote monitoring immediately alerts the police. Fire protection system: Where there s smoke, there needn t be fire. Aside from the mechanical components, it is above all the electronics which pose the danger of fire breaking out in a WTG. Our solution: a smoke detection and fire extinguishing system. The smoke alarm system works quickly and uses dual detector dependency to prevent false alarms. But if a fire still manages to break out, the fine-spray extinguisher automatically activates and effectively puts out the fire.

3 Four options with flexible services on a modular basis. Basic Reliable service for your wind turbine on a regular basis. Basic covers all your basic maintenance needs. This includes all maintenance materials including small parts as well as labor, expenses and all necessary tools for completing the job. Of course, you can always improve your WTG with further services, such as paid upgrades or additional testing procedures, can be ordered as needed. Basic Modular When you re not quite ready for a full maintenance contract, but are looking to extend your basic maintenance package with additional services tailored to your needs, then Basic Modular is the answer. It offers you a wide range of extras ranging from upgrades and rotor blade services to drive train analysis, including frequency converter monitoring and video endoscopy. You have the need, we have the possibilities. Complete Modular It already includes many services, such as remote monitoring, the wear parts package and fault elimination. It even gets more exclusive than that: In addition to the selection of a wide variety of upgrades or an availability guarantee, you alone decide whether or not large components will be part of your service agreement. Complete Your all-inclusive service package. Not only does Complete take all your worries away, it also minimise your risks. This includes the replacement of large components. A wide range of upgrades are also available depending on the turbine type to increase your WTG s safety and/or availability. Complete allows you to conclude contracts with flexible durations. We would be happy to provide you with competent advice on how to choose the best coverage for your needs. Four levels of security. Subsidiary insurance for all service packages is available through an independent insurance broker, whom we have known for many years and who will subsequently represent your interests. A master agreement has been developed to cover your remaining risks. This will provide insurance protection perfectly tailored to your project at attractive conditions. Please contact us if this is required!

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6 Service modules Maintenance Includes all maintenance materials and small parts, maintenance of bolts and any costs of disposal Including labor, expenses and all tools required for this work Based on the maintenance specifications (manufacturer) and extended maintenance documents (Availon) Module 1: Remote monitoring 24/7/365 Permanent surveillance of your WTGs (24/7) Immediate processing of received fault messages (also on weekends and public holidays) Faults are remedied online (where possible) by trained staff offering operators technical phone support Module 5: Unscheduled Maintenance Remedying of all faults, requiring a call out Including labor, expenses and all tools required for the unscheduled maintenance Does not include damage to major components and damage caused by force majeure Also on Sundays and public holidays Please read the *footnote for Basic Modular Module 6: Maintenance of frequency converter (GE ) Including labor, expenses and work and travel time Technical availability (TA) is calculated as follows: AE = (8.760 x N) DT (8,760 MH) x N AE: Availability achieved in the contractual year N: Number of WTGs covered by this agreement DT: Total time (hours) during which, according to the fault list, the WTG(s) was (were) technically unavailable during the contractual year MH: Normal annual maintenance time (hours) 8,760: Hours per year (365 x 24 hrs) Module 2: Wear parts package Includes the following material without installation: Vestas / Gamesa wear parts Replacement of air/oil/water hoses Generator carbon Independent power supply LCTU brass core + lubricant Hydraulic accumulator GE wear parts UPS rechargeable battery pack Yaw brake pads (types A and B) Hose lines Secondary brake pads (BSFH 300, BSFI) Diaphragm accumulator (0.32 l) Slip-ring gearbox carbon Generator carbon ( mm) Battery trays Carbon brushes for pitch motors Module 3: Oil change Changing of oil and oil filter of the main bearing, of the yaw gear ring/pitch system and of the hydraulics (if applicable) Including labor, expenses and all tools required for this oil exchange Module 4: Maintenance of rotor blades At two-year intervals Inspection of the leading and trailing edge of the rotor blade as well as to the pressure and suction side Resistance measurement of the lightning protection system Inspection of the lightning receptor(s) for damage Inspection of the glued connections of the rotor Inspection of the rotor blade seals for cracks, structural damage and function Cleaning of the drainage holes (if applicable) Inspection of the flow elements and the edge protection tape (if applicable) Detailed report including images Repairs up to four man hours included (rotor blade repairs beyond this can be covered by choosing module 7 [major components]) Module 7: Major components Replacement and repair of major components Including materials, expenses, labor, all tools required and costs of crane for this work Please read the *footnote for Complete Modular Major components Vestas / Gamesa Rotor blades Casting part of hub Blade bearings Base frame Yaw gear ring Gearbox Generator Tower Main bearing and main shaft (incl. main bearing housing) Transformer (if integrated in WTG) Major components GE Rotor blades Casting part of hub Blade bearings Base frame Yaw gear ring Gearbox Generator Tower Yaw drive Main bearing and main shaft Frequency converter Transformer (if integrated in WTG) Module 8: Availability guarantee 95 % average technical availability for 1-2 WTGs 97 % average technical availability for 3 or more WTGs Where a service agreement applies to more than one WTG, the average technical availability of all WTGs of the agreement is decisive (availability of wind farm) Please read the *footnote for Complete Modular Module 9: Technical availability (TA), calculation and report Contains a monthly and annual evaluation of the technical availability and production data Including monthly provision of results and data directly to the client Module 10: Safety component inspection and replacement if necessary Including annual inspection and replacement of all system components of the WTG requiring testing and monitoring as required (for basic and basic+modular contracts excl. climb assist system and elevator) Including travel expenses of service technicians used for this purpose Excluding costs of external TÜV staff Module 10 for Vestas V80/V90 (2 MW) / Gamesa G8x/G9x (2 MW) Every Vestas V80/V90 contains rescue equipment and a service lift. The following is checked: Ladder and climb assist system Rescue equipment (for each WTG of 1 MW or more) Crane Service lift (for each WTG of 1 MW or more) Personal fall protection equipment (e.g. belt, safety rope and fall absorber) Every 2 years: Fire extinguishers, helmet and first aid box (if applicable) Module 10 for Vestas V52 (850 KW) / Gamesa G5x (850 KW) The following is checked: Ladder and climb assist system Crane Personal fall protection equipment (e.g. belt, safety rope and fall absorber) Every 2 years: Fire extinguishers, helmet, rescue gear and first aid box (if present in WTG) Module 10 for GE A service lift is not included in this category but could be ordered as an option. WTGs with a hub height of 100 m were only supplied with a service lift from a certain year of manufacture onwards The following is checked: Ladder and climb assist system Crane Personal fall protection equipment (e.g. belt, safety rope and fall absorber) Service lift (if WTG contains lift) Every 2 years: Fire extinguishers, helmet, rescue gear and first aid box (if present in WTG)

7 Module 11: Testing according to DGUV regulation 3 (formerly BGV A3) & SF6 testing** Testing according to DGUV regulation 3 Recommended every four years; every year for mobile devices Includes electrical installation check According to the requirements of DGUV regulation 3 testing, DIN VDE and VDS clause 3602 Including inspection, functional testing and measuring (including measuring report) SF6 inspection Includes visual inspection of the SF6, a torque check for end seals, connection cleaning, SF6 gas check functional check of triggering relay Including labor, expenses and all tools required for this work Internal archiving of measured data and images (in case of abnormalities) Including measuring or damage report for client (in case of abnormalities) Including materials, expenses, labor and all tools required for the work Module 13 XXL: Inspection of drive train XXL Installation of a CMS device Permanent monitoring of system Regular evaluation and reporting of data of CMS measuring (in case of abnormalities) Including materials, expenses, labor and all tools required for the work Module 12: Maintenance of external transformer station for GE General visual inspection and checking the MV system Checking all bolted contacts and switch mechanisms Including cleaning and relubrication of drives Trial switching including checking the auxiliary switches and of open circuit triggers Cleaning of entire MS system Oil transformer General visual inspection of transformer Checking cable connections on MV and LV side Checking oil level and seal Checking transformer guard Cleaning of transformer Low voltage (LV) system/ compensation system General visual inspection and checking the LV system Checking all bolted contacts and switch mechanisms Trial switching including checking the auxiliary switches and open circuit triggers (if applicable) Cleaning of entire LV system Transformer room and accessory Cleaning of transformer room Checking function, completeness and station accessory Grounding measurement Module 13 L: Inspection of drive train L Annual manual measuring of the drive train on site by frequency analysis using a peak analyzer and visual inspection Including materials, expenses, labor and all tools required for the work Archiving of measured data and images (in case of abnormalities) Including measuring or damage report for client (in case of abnormalities) Module 13 XL: Inspection of drive train XL Annual manual measuring of the drive train on site by frequency analysis using a peak analyzer and video endoscopy All specifications in these tables are non-binding. They are only examples and are not to be misconstrued as actual terms of contract. The terms and conditions of each contract are subject to the explicit agreements of the contracting parties. * This module is only available when combined with at least one other specific module. Please contact our sales department. ** Performance exclusively applies to Germany and is based on German legal principles and guidelines.

8 Optimisation modules Modul 14: Upgrades Vestas Carbon brush package available for V52, V66, V und V New mounting concept with innovative new hybrid carbon brushes Even wear on leading and trailing side Conservation of sliprings Quick and simple replacement of carbon brushes Safe and quick handling of installation work 200 % potential increase in service life of carbon brushes Extends change intervals to a potential 3 years depending on location Reduces replacement costs Transformer ventilation package available for V66, V and V More efficient ventilation package for transformer Special deflectors guide the air through the nacelle Transformer supplied with preheated and filtered cooling air Prevents soiling, e.g. salt deposits Increased service life Slip-ring box air extraction available for V66, V and V Accurate extraction of air from the slipring room Automatic removal of graphite dust in air current Minimizes susceptibility to faults (increased temperatures, spark formation, flashovers, short-circuiting) Eliminates the need for additional troubleshooting calls Reduces labor and expenses Prevents damage to generator and total failure Yaw drive monitoring available for V and V class MK1 to MK5 Measuring of current consumption of individual actuators Deviation from normal operation is immediately apparent(plc compares rated current < > idle current) Main controller reacts with emergency program (e.g. reduction of tracking steps) Automatic fault reporting to operator and service staff (GSM modules) Repairs can be planned and carried out promptly Short and plannable disruptions to production Minimum loss of yield Rotor cable replacement available for V80 VCS 2.0 Diagnosis of overheating during visual inspection (damaged cable must thus be replaced) Cable to be replaced with cable with larger diameter Also effective during higher loading and strong-wind phases Special tools and work processes developed for this operation ensures an efficient replacement No need for an external crane Prevents overheating in the area of the rotor cables of the generator Prevents irreversible damage and loss of yield Arc sensor available for V66, V80 2.0, V Constant monitoring of the creation of arcs by 2 sensors (photoelectric cells) Additional third sensor directly in control cabinet next to circuit breaker Save deactivation of SF6 medium voltage switchgear within milliseconds Permanent monitoring of copper rail main distribution Prevents serious fires and total loss Permanent lubrication system for yaw gear available for V and V Constant lubrication of yaw pinions and gear teeth Prevents corrosion (no corrosion no wear) Permanent, even lubrication film on gears Improves WTG performance Module 14: Upgrades for Gamesa Permanent lubrication system for yaw gear ring available for G8x-type turbines Constant lubrication of yaw pinions and gear teeth Prevents corrosion (no corrosion no wear) Permanent, even lubrication film on gears Improves WTG performance Arc sensor available for G8x and G9x Constant monitoring of the creation of arcs by 2 sensors (photoelectric cells) Additional third sensor directly in control cabinet next to circuit breaker Save deactivation of SF6 medium voltage switchgear within milliseconds Permanent monitoring of copper rail main distribution Prevents serious fires and total loss Remote monitoring for Gamesa WTGs Remote troubleshooting, if conditions permit User-specific visualization of all open data points Collection of statistical fault frequencies Permanent monitoring of your turbines (24/7/365) Immediate processing of received fault messages (also on weekends and public holidays) Module 14: Upgrades for GE Bypass filtration system Filtration of particles and oil ageing products of at least 3 μm (standard from 10 µm) Potentially longer oil life due to efficient cleaning of gearbox oil Longer intervals for changing gearbox oil (60 months+) Additives remain dissolved in gearbox oil Position monitoring of gearbox Permanent monitoring of gearbox position by two sensors Early detection of potential damage on main bearing Automatic stop in case of positional change (gearbox is not damaged) Immediate fault notification via remote monitoring Prevents costly consequential damage caused by increased loading in planetary bearing Grid coupling contactor Relieves the circuit breaker as protection element against overcurrent and undervoltage Reduces switching operations to max /year (otherwise approx. 2,500-3,000) Designed for 250,000 switching cycles at rated current Prevents increased wear, thermal overloading, malfunctioning Prevents nearly all damage to FC and generator caused by the malfunctioning of the circuit breaker Installation and configuration for each WTG in no more than 2 days Permanent lubrication system of main bearing Permanent lubrication and supply Self-contained system for each separate bearing Prevents double lubrication during maintenance Lower wear Prevents excessive and insufficient lubrication Increases the service life of the main bearings Permanent lubrication system for generator bearing Permanent lubrication/supply of fast running generator bearing Self-contained system for each separate bearing Prevents double lubrication during maintenance Lower wear Prevents excessive and insufficient lubrication Increases the service life of the generator bearings These modules are available for selected Vestas, Gamesa, and GE turbine types on inquiry. The service packages are available for Germany, Austria, Switzerland, Italy, Spain, Portugal and Poland. All contracts are available in German and English. GE is a registered trademark of GENERAL ELECTRIC COMPANY, US. Gamesa is a registered trademark of Gamesa Corporación Tecnológica, S.A., Spain.

9 14.55 Permanent lubrication system of yaw gear Permanent lubrication yaw pinions/gears Prevents corrosion Additionally installed weather protection directly catches any dripping lubricant Prevents further soiling of tower and contamination of the environment Improves provision of cooling air to the drive train through additional ventilation hole in nacelle floor Permanent lubrication system of pitch gear ring Permanent, even lubrication film on gears Hard foam pinion supplies the gear of the drive with a thin, even lubricating film Relieves the gear rings of the rotor blades Only ¼ of the gear ring is loaded during operation No corrosion no wear Improves WTG performance Prevents costly distortion of blade bearing Maintains WTG s operational reliability Certified repair procedures Short downtimes Damage repair via welding procedure in accordance with DIN EN ISO I1 Prevention and/or delay of recurrent crack formation in components under dynamic loads Lifetime service concepts Permanent monitoring and repair up to the end of the operating time of the WTG One-time repair on a time/material basis Radii relieve small cracks Includes measuring of machine base frame (photogrammetry) Axis cabinet ventilation Optimal and Permanent ambient temperature of pitching battery is ensured by battery heating and insulation of control cabinet Prevents heat loss and premature failure of battery caused by cold Increases the service life of the pitching battery Prevents major fluctuations in temperature Pitching batteries require less frequent changes Ice-free sensors Weather sensors with high-performance 230V heating Prevents icing over of anemometer and wind vane Guarantees normal operation of the WTG even under extreme temperatures Temperature range of between 40 C and +60 C High mechanical stability due to double-screened stainless steel ball bearings (anemometer) Maximum accuracy due to magnetically dampened wind vane Worldwide tried-and-tested system Module 15: WTG inspections To be checked approx. every 12 month on request Non-destructive material testing Visual condition check Dye penetration test for detecting cracks Crack inspection via magnetic particle testing Ultrasound inspection if necessary Documentation and photos Special test methods for different types of gearbox in their installed state Checking for cracks/lateral cracks on rotor shaft below the seat of the main bearing Examination of concrete foundations and reinforcement (Ground Penetration Radar) Examination of mounting bracket (UT Phased Array Technology) 08/2016

10 An overview of our Service modules Maintenance Remote monitoring 24/7/365 Wear parts package Oil exchange Maintenance of rotor blades Unscheduled Maintenance Major componen Maintenance of frequency convert Basic Basic Modular Complete Modular Complete Optimisation modules Upgrades for Vestas Carbon brush package Slipring box suction system Yaw drive monitoring Ventilation package transformer Replacement of rotor cables Arc sensor Remote monitoring for Gamesa WTGs Upgrades GE Permanent lubrication system yaw gear ring Upgrades for Gamesa Permanent lubrication system of yaw gear Arc sensor Bypass filtration system Position monitoring of gearbox Permanent lubrication system of main bearing Grid coupling contactor Permanent lubrication system of yaw gear Permanent lubrication system of generator bearing Permanent lubrication system of pitch gear ring Axis cabinet ventilation Ice-free sensors WTG inspections Non-destruc Vi

11 service packages. VIncluded in the contract O Optional Not included in the contract ts er (GE ) Availability guarantee Technical availability, calculation and report Safety component inspection and replacement if necessary Testing according to DGUV regulation 3 & SF6 inspection Inspection of drive train XL External maintenance for GE transformer station Inspection of drive train L L 13 XL 13 XXL Inspection of drive train XXL tive material testing sual condition check Crack inspection via magnetic particle testing Ultrasound inspection if necessary Dye penetration test for detecting cracks Documentation and photos Check for cracks/lateral cracks on rotor shaft Examination of concrete foundations and reinforcement Special test methods for different types of gearboxes Damage repair via welding procedure Examination of mounting bracket (UT Phased Array Technology) Maintains WTG s operational reliability Certified repair procedures Short downtimes One-time repair on a time/material basis Radii relieve small cracks Prevention and/or delay of recurrent crack formation Lifetime service concepts Permanent monitoring and repair Includes measuring of machine base frame Basic Basic Modular Complete Modular Complete * This module is only available when combined with at least one other specific module. Please contact our sales department.

12 At home anywhere in the world. Outstanding service knows no boundaries. Our comprehensive service offers attest to that. That s why we are on hand to provide you with our service offers in more and more countries all over the world. Service solutions Energy management Material testing Find out more at Headquarters: +49 (0) Remote Monitoring: +49 (0) carbon neutral windservice@availon.eu print production natureoffice.com DE /2016 Availon GmbH Daimlerstraße Rheine Germany A Wind Systems A/S company