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Contents Page Axis cabinet ventilation 04 Diagnosis of base frame/generator support 04 DGUV Regulation 3 testing 05 Remote monitoring for Gamesa WTGs 06 Gearbox position monitoring 07 IceFree sensors 07 LED beacon light 08 Arc sensor 08 Bypass filtration 09 Grid coupling contactor 09 Permanent lubrication systems 10 Access monitoring 11
03 The best thing that can happen to your wind farm. Being added to the Vestas family is a real upgrade for Availon. As a world-class company, we can raise our capacity as a service provider to a completely new level for you and for customers in more and more countries all over the world. That s what we see as Strong.Partnership. This strong partnership will enable us to help you maintain a smooth operation of your WTG and to optimize your yields even more effectively in the future. After all, by taking advantage of new synergies, we expand our service competences, are able to serve an even broader spectrum of WTG technologies and keep them at the state of the art at all times. The benefits for you: Thanks to new, tailor-made upgrades, innovative solutions and certified tests, you will increase the value and profitability of your turbine more quickly. We conduct high-precision material testing to prevent damages more effectively and thus avoid failures and losses in yield. And our perfectly networked remote monitoring systems ensure the smooth operation and safety of your turbine more dependably than ever. We are looking forward to working further on the successful future of your wind farm. You can find out what our contribution could look like on the following pages. Gamesa is a registered trademark of Gamesa Corporación Technológica, S.A., Spain. GE is a registered trademark of GENERAL ELECTRIC COMPANY, US.
04 Axis cabinet ventilation. The weather not only has an influence on the immediate surroundings of a WTG. If it turns warmer or colder on the outside, the temperatures inside the nacelle also change accordingly. This is not necessarily an ideal environment for sensitive components, such as the accumulators, which often react to major temperature fluctuations with a reduced service life. Two challenges were at the heart of the search for a solution: preventing cold-related failures and avoiding heat loss in the control cabinet. The climate concept developed for this from battery heating and insulation permanently ensures the optimum and continuous environmental temperature of a pitching battery within the control cabinet. Overview of benefits and features of axis cabinet ventilation: Increase of pitching battery service life Optimum and continuous environmental temperature thanks to battery heating and insulation Avoidance of heat loss and temperature fluctuations in the axis cabinet Pitching batteries require less frequent changes Diagnosis of base frame / generator support. A good wind location brings with it many challenges for materials and technology. Base frames and generator supports are subject to enormous traction and bending torque. The result can be cracks and unstable weld seam connections and can lead to particularly costly and time-consuming repairs. Together with WPT-Nord, the experts in non-destructive material testing, Availon has many years of experience and the expertise to ensure the quality of base frames and generator supports for the long term. All this whilst meeting nationally and internationally recognised certification requirements. Overview of the benefits and features of diagnosis of base frame / generator support: Maintains WTG s operational reliability Checking generator support for cracks (magnetic powder test) Ultrasound inspection if necessary Welding and sanding preventative measures with the removal of tension peaks Abolition of cracks using MAG, E and WIG welding procedures Prevention and/or delay of recurrent crack formation in steel components under dynamic loads
06 DGUV Regulation 3* Testing (formerly BGV A3). The consistent checking of the complex electronics of a WTG has not yet been established, even though it has been a legal requirement for several years now. And rightly so, as electrical accidents lead to serious burns and, in the worst case, death. Together with ABO Wind, Availon has developed the first DGUV Regulation 3 testing especially for WTGs. Taking into account the various WTG types, every use follows its own turbine-specific plan. Over 150 measurement points as well as kilometres of cables are responsibly tested, taking into account all legal requirements. Overview of benefits and features of DGUV Regulation 3 testing: Upholds the safety of the electrical equipment in WTGs According to the requirements of DGUV Regulation 3 testing, DIN VDE 0105-100 and VDS clause 3602 Avoids accidents with serious consequences due to electrical faults Reduces the liability risk for operators First DGUV Regulation 3 testing process especially for WTGs Seamless documentation including detailed description and, if necessary, photos Implementation recommended every four years; for mobile devices: annually * Performance exclusively applies to Germany and is based on German legal principles and guidelines.
07 06 Remote monitoring for Gamesa WTGs. The possibility of remotely observing a WTG allows the read-out of production and condition data of the system as well as the rectification of problems without having to be on-site. Unfortunately, until now this has only been possible via the remote monitoring of the OEM, creating a certain level of dependency. Together with renowned partners, Availon has developed a system that makes it possible to read out data from your wind farm. Almost all open data points of the system are available and the rectification of faults can be done online. In addition, Availon is available to the operator by phone for any technical questions. Overall, this creates an independent and efficient remote monitoring of your wind farm. Overview of benefits and features of remote monitoring for Gamesa WTGs: Remote troubleshooting (if conditions permit) User-specific visualization of all open data points Collection of statistical fault frequencies Permanent surveillance of your WTGs (24/7) Immediate processing of incoming fault messages (also on Sundays and public holidays) Read-out and preparation of production figures Manufacturer-independent remote monitoring
07 Gearbox position monitoring. In the event of an undetected main bearing washer breakage, even the gearbox moves backwards by up to 9mm and is axially only limited by the pedestal bearing. The pressure of the power train is transferred to the planet carrier bearing. The consequence: damage to the entire planet carrier bearing and therefore the entire gearbox. The position of the gearbox can be consistently monitored with the solution by Availon. Two inductive proximity switches register every change in position and immediately pass these on as a notification to remote monitoring. Overview of benefits and features of gearbox position monitoring: Permanent monitoring of the gearbox position with two inductive proximity switches Avoidance of massive gearbox damage Seamless connection of turbine control and remote monitoring Automatic stop of the turbine upon a fault notification IceFree sensors. Below-zero temperatures barely have an effect on gearbox oil. But this is somewhat different on the outside of the nacelle. Even at temperatures around freezing level there can be cracks in the anemometer and the weather vane. In this case, the only option is the use of a service team. Or better weather. Both scenarios require a lot of time. By which point the sensors are measuring a wind speed of 0.0 m/s. Meaning the turbine is stopped due to the fault notification and does not produce any yields in spite of the wind. Losses of up to 5,000 per turbine and winter period are not uncommon. IceFree sensors provide help here as they are able to withstand even extreme below-zero temperatures with their tested heating concept. The solution is not only very robust and set up for a temperature range of -40 C to +60 C. The magnetically damped wind vane also ensures a high level of measurement precision. Overview of benefits and features of IceFree 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
08 LED beacon light. Wind turbine generators are getting taller and taller. But they are also intruding on an area critical for air traffic. WTGs must therefore be identified above a total height of 100 m. The beacon light plays an important role in this, but is exposed to adverse weather conditions. Availon offers a tested LED beacon light system for WTGs. LEDs are unbeatable when it comes to efficiency and reliability. This low maintenance and wear system ensures a higher level of safety and makes the costly replacement of conventional bulbs and other components redundant. Overview of benefits and features of LED navigation lighting: Plug & play: works as soon as the power supply is provided Highly efficient LED system Minimal maintenance and wear Hard-wearing, even in adverse weather conditions Increases the safety of the WTG Arc sensor. Experience shows that arcs can also occur in the control cabinet of the circuit breaker and even cause fatal fires. Arcs occurring in this way are not recognized by the two available arc sensors. A third arc sensor is installed in close proximity to the circuit breaker to monitor the copper rail main distribution. If an arc occurs there, the turbine is immediately taken off the grid. Overview of benefits and features of the additional arc sensor: Permanent monitoring of copper rail main distribution Additional third sensor directly in control cabinet next to circuit breaker Safe deactivation of SF6 medium voltage switchgear within milliseconds Prevents serious fires and total loss For G8x and G9x turbines
09 Bypass filtration. Oil is a decisive factor for the duration of a gearbox. However, the technology of many turbines only allows the filtration of particles and oil ageing products from a size of 10 µm. Smaller particles remain in the oil and lead to permanent damage of the gearbox. The engineers at Availon have developed an additional system that filters out all particles and oil ageing products from a size of 3 μm in the bypass flow. Overview of benefits and features of bypass filtration: Filtration of particles and oil ageing products from a size of 3 µm (standard from 10 µm) Potentially longer oil life due to efficient cleaning of gearbox oil The change interval of the gearbox oil can be increased to 60 months or more Additives remain dissolved in gearbox oil Grid coupling contactor. In the event of under and overvoltage, for example due to a storm, every WTG must switch itself off and later reconnect. This task is undertaken by the circuit breaker, with 2,500 to 3,000 cycles every year. As the precision mechanism is heavily stressed by this, the maintenance costs become that much higher. A faulty circuit breaker can also lead to major damage to the converter and generator. The grid coupling contactor developed by Availon reduces the cycles of the circuit breakers to a maximum of 20 to 30 per year. This significantly increases the service life of the circuit breaker. Overview of benefits and features of the grid coupling contactor: Increase of turbine safety Takes on the majority of regular cycles (up to 250,000) Significant increase of service life of the circuit breaker by reducing cycles to a max. of 20 30 per year Prevents increased wear, thermal overloading, malfunctioning Avoids consequent damage to the converter and generator Reduces maintenance costs Increases turbine availability Installation and configuration for each WTG in no more than 2 days
10 Permanent lubrication systems. Be it open gear teeth, planetary stages or roller bearings, the moving mechanical components in wind turbine generators perform a task that is as difficult as it is greasy. After all, the right lubrication contributes towards less wear and better corrosion protection. However, a perfectly even lubrication film is required to avoid excess grease. And this is hard to achieve even for experienced engineers. The permanent lubrication systems by Availon automatically and optimally supply every moving component with lubrication. Be it for yaw gears, main bearings, generator bearings or pitch gears. Every permanent lubrication system guarantees a perfectly even lubrication film and thereby ensures better corrosion protection and less wear. The grease container has to be replaced once per year. The maintenance work required is reduced to a minimum. Overview of benefits and features of permanent lubrication systems: More safety thanks to permanent, continuous lubrication supply Permanently even lubrication film Avoidance of excessive and insufficient lubrication Better protection against wear and corrosion Reduction of maintenance and repair works The grease cartridge has to be replaced just once per year A breakdown of the special benefits and features of permanent lubrication systems: The permanent lubrication system of yaw gears: Constant lubrication of yaw pinions and gear teeth Prevents corrosion Additionally installed weather protection directly catches any dripping lubricant Prevents further soiling of tower and contamination of the environment For GE 1.5 MW and G8x turbines The main bearing permanent lubrication system: Continuous lubrication and supply Independent turbine for each separate bearing Prevents duplicate lubrication during maintenance Increases the service life of the main bearings The permanent lubrication system for generator bearing: Continuous lubrication/supply of fast running generator bearing Independent turbine for each separate bearing Prevents duplicate lubrication during maintenance Increases the service life of the generator bearings The permanent lubrication system of pitch gear rings: 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
12 12 Access monitoring. If thieves tamper with WTGs, they often do so with little expertise, but great criminal energy. Possible consequences: major damage due to stolen copper cables and destroyed WTG installations. Possible defence: Availon access monitoring. As those who ignore the warning sign on the WTG set off more than they might think: along with the acoustic alarm directly in the WTG, a message is immediately sent to the remote monitoring. They are able to listen via an acoustic sensor on the inside of the WTG. If nothing can be heard and there is no longer anybody in the entry area, the warning alarm switches off. Otherwise, the police are immediately informed. Overview of benefits and features of access monitoring: Solution independent of WTG control Movement sensor and remote monitoring are directly connected via GSM modem Immediate alarm and reaction to break in attempts Acoustic alarm directly in the turbine Acoustic sensor on the inside only available when combined with monitoring camera Prevents damage, downtimes and yield cuts Can also be used for transformer or transfer stations
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 www.availon.eu Headquarters: +49 (0) 5971 8000-0 Remote Monitoring: +49 (0) 5971 8000-1010 E-mail: windservice@availon.eu 08/2016 Availon GmbH Daimlerstraße 40 48432 Rheine Germany www.availon.eu A Wind Systems A/S company