vestas.com Condition Based Maintenance of Vestas Offshore Turbines European Offshore Wind Conference & Exhibition 2009, Stockholm Jacob Juhl Christensen, Product Manager
Dec 22, 2015
vestas.com
Condition Based Maintenance of Vestas Offshore Turbines
European Offshore Wind Conference & Exhibition 2009, StockholmJacob Juhl Christensen, Product Manager
2 | Condition Based Maintenance of Vestas Offshore Turbines, April 19, 2023
Agenda
• Condition Based Maintenance enabled by Condition Monitoring
• Technical and operational challenges in fleet-wide implementation
• Practical implementation of condition based maintenance in service organisation
3 | Condition Based Maintenance of Vestas Offshore Turbines, April 19, 2023
Condition Based Maintenance enabled by Condition Monitoring
• Condition Monitoring: Assessment of the "health" of a machine by analysis of measured signals (vibration, temperature, …)
• Estimation of time of failure optimised planning of maintenance activities
Breakdown(Ad Hoc)
Preventive(Scheduled)
Predictive(Condition based)
Mai
nte
nan
ce
Str
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ies
Condition Monitoring
4 | Condition Based Maintenance of Vestas Offshore Turbines, April 19, 2023
Condition Monitoring System
• Measurement system on WTG Drive Train:
5 | Condition Based Maintenance of Vestas Offshore Turbines, April 19, 2023
Condition Monitoring Information Flow
6 | Condition Based Maintenance of Vestas Offshore Turbines, April 19, 2023
Fault detection by historical trending of Fault Symptoms
• Failure modes• Bearing Faults
• Coupling Faults
• Misalignment Faults
• Gear Faults
• Unbalance
• Support Structure Faults
• Examples of trended parameters
• Overall RMS
• High Frequency Bandpass Values
• Tooth Mesh Frequencies
• Bearing Frequencies
• etc.
7 | Condition Based Maintenance of Vestas Offshore Turbines, April 19, 2023
How to achieve cost efficient condition monitoring on a large and geographically dispersed fleet ?
• Technical Challenges• Events in each turbine can
lead to a cascade of alarms• Requirement: only one alarm
per detected fault/severity level
• The severity of all alarms must be assessed
• Need for automated alarm management
• Operational Challenges• Site managers need clear
advice about how to plan service actions according to alarm severity.
8 | Condition Based Maintenance of Vestas Offshore Turbines, April 19, 2023
Automatic Alarm Management – NO Alarm Flooding
• Reliable fault detection requires monitoring of 1000+ alarm limits per turbine.
• Alarm Flooding is avoided by filtering the fine grained alarm information down to one single alarm notice per physical fault.
• The Severity of the potential damage is estimated by the Alarm Manager from the indications in the alarm pattern.
• Final severity assessment performed by a diagnostic expert
9 | Condition Based Maintenance of Vestas Offshore Turbines, April 19, 2023
Severity classification – Actionable information
• Alarms are classified according to severity• New alarms are issued only when a new severity level is reached• A maximum of 4 alarm notices will be issued during the “lifetime” of a
fault• Each severity class specifies a lead time until recommended service
action.
10 | Condition Based Maintenance of Vestas Offshore Turbines, April 19, 2023
Reporting – Clear advice about severity and estimated remaining life time
• Diagnose of detected potential failures are summarized in an Alarm Report
• Fixed report format with clear split between
• Observation• Interpretation• Assessment of maintenance needs
11 | Condition Based Maintenance of Vestas Offshore Turbines, April 19, 2023
Planning of service actions according to alarm severity
• Due to high mobilization costs, unnecessary turbine visits must be avoided.
• Rules for when to perform a turbine inspection as function of the alarm severity class must be defined.
Severity Type Planning of inspection
1 Danger Within 24 hours or remote stop until access possible
2 Alert ASAP (within two weeks)
3 Alert Next scheduled visit
4 Alert Next scheduled visit
5 Good No action
6 System Next scheduled visit
12 | Condition Based Maintenance of Vestas Offshore Turbines, April 19, 2023
Summary
Condition Based Maintenance on offshore turbines requires
• Online Condition Monitoring systems
• Automated Alarm management
• Alarms transformed into actionable information
• Planning of service actions according to alarm severity
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