WTG service tailor - made: Our maintenance and optimization modules. Multibrand from Vestas速 to GE速.
WE LISTEN.
Recommended by independent 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.
DALFI 1979 generator: A six ton milestone. The DALFI generator is a joint development with SSB Duradrive GmbH. The stator and rotor have been dimensioned and designed to optimize its efficiency with high speed variability, an efficient cooling concept and much more. All with an extended service life.
Internal crane system: Heavy loads made easy. The use of heavy-duty cranes is associated with a great deal of work and high costs. The internal crane system from Availon is an alternative. With a weight of just 200 kg, it can be used quickly and flexible. Long waiting periods and downtimes are avoided, and the expensive deployment of a heavy-duty crane is a thing of the past.
LED obstruction lights: A bright spot on the horizon. 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 temperaturesensitive line reactor is protected by means of high-performance diagonal fans.
Control box: 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.
Reinforced transformer bracket: Advantages that quicken your pulse. A transformer is subject to high levels of vibration. They can be so strong that the transformer bracket can break, causing the transformer to tilt or hang on one side. Our solution makes use of the crane runway and uses steel rods to reinforce the transformer bracket.
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: 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 moniting immediately alerts the police.
Each telephone call is an investment: In the future. We don't just claim that calling us is well worth the effort – we can prove it too. In addition to developing special service provisions at our competence centers in Rheine and Hamburg, we also develop upgrades, that ensure even older turbines run efficiently and economically in the future or, even better, become more profitable. This pays off, particularly for you. For example, with yaw monitoring for Vestas® types V80 and V90.
A telephone call is well worthwhile. An e-mail, too. Find out more about our range of services at www.availon.eu, send us an e-mail or call us. We look forward to hear from you. Headquarters: +49 (0) 5971 8025-0 Advice: +49 (0) 5971 8025-210 Remote Monitoring: +49 (0) 5971 8025-250 E-Mail: windservice@availon.eu
Availon GmbH | Jacksonring 2 | 48429 Rheine | Germany | www.availon.eu
Four options with flexible services on a modular basis. WindKeeper®
WindKeeper®
Basic
Basic Modular
Reliable service for your wind turbine on a regular basis. WindKeeper® 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. Subsequent services for improving your wind turbine can be ordered as needed, such as paid upgrades or additional testing procedures.
When you’re not quite ready for full-main tenance coverage, but are looking to extend your basic maintenance package with additional services tailored to your needs, then WindKeeper® 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. When the need arises we respond with a choice of possibilities.
WindKeeper®
WindKeeper®
Remote monitoring, a wear parts package and fault elimination are just a few of the basic services included in WindKeeper® Complete Modular. This service package can be made even more exclusive with a choice of upgrades or an availability guarantee as well as the opportunity to choose whether major components are covered in your service contract. As with WindKeeper® Basic and WindKeeper® Basic Modular, this service contract can be concluded up to the 15th year of your WTG’s operation.
Your all-inclusive service package. Not only does WindKeeper® Complete take all your worries away, it also minimizes your risks. This includes the replacement of major components and, depending on turbine type, up to six upgrades – regardless of whether it is to increase the safety or the availability of your WTG. WindKeeper® Complete also offers flexible-term contracts. We would be happy to provide you with competent advice on how to choose the best coverage for your needs.
Complete Modular
Complete
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!
Maintenance • 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) • Certified by Germanischer Lloyd (GL) Module 1: Remote monitoring • Permanent surveillance of your WTGs (24/7) • Immediate processing of received fault messages (also on weekends and public holidays) • Faults are (where possible) remedied online by trained staff offering operators technical phone support Module 2: Wear parts package • Includes the following material without installation: Vestas® Wear parts Replacement of air/oil/water hoses Generator power brushes Generator grounding brushes Independent power supply LCTU brass core + lubricant Hydraulic accumulator GE® Components Wear parts UPS ......................................................... Battery pack Yaw brake .............................................Pad - type B Pad - type A Hoses Secondary brake ............................. Brake pads - BSFH 300 Brake pads - BSFI Diaphragm accumulator ............ 0.32l Slipring gearbox ............................... Power brushes Generator .............................................Power brushes 50 to 100 mm Battery trays ...................................... Battery trays Pitch motors ...................................... Carbon brushes Module 3: Oil exchange • 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 • Inspection of the leading and trailing edge of the rotor blade as well as to the pressure and suction side on cracks, erosion, paint damage or other damages • 4-point measuring of the lightning protection system • Inspection of the lightning receptor(s) for damage caused by lightning strikes • Inspection of the glued connections of the rotor blade on air inclusions, cracking and peeling • Inspection of the rotor blade seals for cracks, structural damage and functionality • Cleaning of the drainage holes (if applicable) • Inspection of the flow elements and the leading edge protection tape (if applicable) • Detailed report including images • Repairs up to four man hours included Module 5: Unscheduled Maintenance • Remedying of all faults, requiring a call out • Including labor, expenses and all tools required • Except for damage on major components and damage caused by force majeure • Also on weekends and public holidays • Please read the *footnote for WindKeeper® Basic Modular Module 6: Maintenance of frequency converter (GE®) • As specified by manufacturer 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 WindKeeper® Complete Modular
Major components Vestas® • Rotor blades • Casting part of hub • Blade bearings • Base frame • Yaw gear ring • Gearbox • Generator • Tower • Main bearing and main shaft • 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 1 to 3 WTGs • 97 % average technical availability for 4 and 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) • Based on 12 hours of rotor blade maintenance every two years • Please read the *footnote for WindKeeper® Complete Modular
Technical availability (TA) is calculated as follows:
AE = (8.760 – MH) 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 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: Maintenance and replacement of safety components • Checking and replacement of all system components of the WTG requiring testing and monitoring as required (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) Every Vestas® V80/V90 contains rescue equipment and a service lift. The following is checked: • Ladder and climb assist system • Rescue equipment (for each WEA of 1 MW or more) • Crane • Service lift (for each WEA of 1 MW or more) • Personal equipment protecting against falling (e.g. belt, safety rope and fall absorber) • Fire extinguishers, helmet and first aid box (if applicable) Module 10 for Vestas® V52 (850 KW) The following is checked: • Ladder and climb assist system • Crane • Personal equipment protecting against falling (e.g. belt, safety rope and fall absorber) • Fire extinguishers, helmet, rescue device and first aid box (if applicable for WTG)
An overview of our service packages.
Module 10 for GE® A service lift is not included in this category but could be ordered as an option. Only from a certain year of manufacture onwards were WTGs with a hub height of 100 m supplied with a service lift. The following is checked: • Ladder and climb assist system • Crane • Personal equipment protecting against falling (e.g. belt, safety rope and fall absorber) • Fire extinguishers, helmet, rescue device and first aid box (if applicable for WTG) • Service lift (if WTG contains lift) Module 11: BGV A3 & SF6 check BGV A3 check: • Checking of the electrical installation • According to the requirements of BGV A3, DIN VDE 0105-100 and VDS clause 3602 • Inspection, functional testing and measuring (including measuring report) • Prompt remedying of minor faults SF6 check: • Visual inspection of SF6, checking of torques on the end seals, cleaning of connections, checking of SF6 gas and functional check of triggering relay • Including labor, expenses and all tools required for this work Module 12: Maintenance of external transformer station for GE® medium voltage switchgear (MS) • General visual inspection including checking of the MS system • Checking of all bolted contacts and switch mechanisms • Including cleaning and relubrication of drives • Trial switching including checking of 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
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Maintenance Modules
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 • 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 this work Module 13 XXL: CMS monitoring and reporting • 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
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WindKeeper®
Basic
WindKeeper®
WindKeeper®
Complete Modular WindKeeper®
Complete
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Optimization modules
Module 14: Upgrades Vestas® 14.01 Carbon brush holders • New fixation concept • Even wear on leading and trailing side • Conservation of sliprings • Quick and simple replacement of carbon brushes • Safe and quick handling of installation work • 50% increase in service life of carbon brushes • Extends change intervals from 1 to 1.5 years • Lowers replacement costs 14.02 Ventilation package transformer • More efficient ventilation package for transformer • Special deflectors guide the air through the nacelle • Only 20 % of the cooling air enters the transformer (sufficient for cooling) • Prevents soiling, e.g. salt deposits • Increased service life 14.03 Slipring box suction system • Accurate extraction of air from the slipring room • Automatic removal of graphite dust in air current • Minizes susceptibility to faults (increased temperatures, spark formation, flashovers, short-circuiting) • Additional call outs are no longer required • Reduces work for service engineer • Prevents damage to generator and total failure 14.04 Yaw drive monitoring • Messuring 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
Basic Modular
Others: • After completion of the maintenance work, the customer is issued a maintenance report 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 material, expenses, labor and all tools required for this work • Archiving of measured data and images (in case of abnormalities) • Including measuring or damage report for client (in case of abnormalities)
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LV system/compensation system • General visual inspection and checking of LV system • Checking of all bolted contacts and switch mechanisms • Trial switching including checking of auxiliary switches and of 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
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Optimization modules
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WindKeeper®
Basic
14.05 Replacement of rotor cables • 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 14.06 Arc sensor • 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 14.07 Permanent lubrication system yaw gear ring • 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 GE® 14.50 Kidney filtration system of main gearbox oil • Checking of 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 • Gearbox oil can be changed less frequently (60 months+) • Additives remain dissolved in gearbox oil
WindKeeper®
Basic Modular WindKeeper®
Complete Modular
14.51 Position monitoring of gearbox • Permanent monitoring of position of gearbox 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
WindKeeper®
Complete
All product, service and technical specifications in these tables are non-binding and not to be misconstrued as actual terms of contract. The terms and conditions of each contract are subject to the explicit agreements of the contract parties. Contracts can be concluded for WindKeeper® Basic, WindKeeper® Basic Modular and WindKeeper® Complete Modular up to the 15th year of operation. Flexible contracts are possible for WindKeeper® Complete on inquiry. * This module is only available when combined with at least one other specific module. Please contact our sales department.
These modules are available for selected Vestas® and GE® turbine types on inquiry. The service packages are available for Germany, Austria, Switzerland, Spain and Italy. All contracts are available in German and English. “Vestas” is a registered trademark of Vestas Wind Systems A/S, DK. “GE” is a registered trademark of GENERAL ELECTRIC COMPANY, US.
14.52 Grid coupling contactor • Relieves the circuit breaker as protection element against overcurrent and undervoltage
• Reduces switching operations to a max. of 20-30/year (normally 2,500 to 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 14.53 Permanent lubrication system of main bearing • Continuous lubrication and supply • Independent system for each separate bearing • Prevents duplicate lubrication during maintenance • Low wear • Prevents excessive and insufficient lubrication • Increases the service life of the main bearings 14.54 Permanent lubrication system of generator bearing • Continuous lubrication/supply of fast running generator bearing • Independent system for each separate bearing • Prevents duplicate lubrication during maintenance • Low wear • Prevents excessive and insufficient lubrication • Increases the service life of the generator bearings 14.55 Permanent lubrication system of yaw gear • Continuous 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
15.04 Examination of foundations 1. Examination of concrete foundations and reinforcement (Ground Penetration Radar) 2. Examination of mounting piece (UT Phased Array Technology Module 15: WTG check – GE® • To be checked approx. every 12 month on request 15.50 Diagnosis of base frame/generator support • Checking generator support for cracks (magnetic powder test) • Ultrasound and X-ray testing on request • Including documentation and photos 15.51 Repair of base frame or Live Time Service 1. One-off repair as required 2. Continuous monitoring and repair up to the end of the operating time of the WTG 15.52 Measuring of machine base frame and generator support • Measuring of machine base frame (photogrammetry) 15.53 Examination of drive train • Checking for cracks/lateral cracks on rotor shaft below the seat of the main bearing 15.54 Examination of foundation 1. Examination of concrete foundations and reinforcement (Ground Penetration Radar) 2. E xamination of mounting bracket (UT Phased Array Technology)
14.56 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 14.57 Axis cabinet ventilation • Optimum and continuous 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 14.58 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 check – Vestas® • To be checked approx. every 12 month on request 15.01 Diagnosis of generator support • Includes checking generator support for cracks (magnetic powder test) • Ultrasound and X-ray testing on request • Including documentation and photos 15.02 Examination of gearbox • To be checked approx. every 12 month on request special test methods for different types of gearbox in their installed state (camera and ultrasound test method) • Including documentation 15.03 Examination of drive train • Checking for cracks/lateral cracks on rotor shaft below the seat of the main bearing
09/2012
Maintenance Modules
Maintenance Modules Maintenance • 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) • Certified by Germanischer Lloyd (GL) Module 1: Remote monitoring • Permanent surveillance of your WTGs (24/7) • Immediate processing of received fault messages (also on weekends and public holidays) • Faults are (where possible) remedied online by trained staff offering operators technical phone support Module 2: Wear parts package • Includes the following material without installation: Vestas® Wear parts Replacement of air/oil/water hoses Generator power brushes Generator grounding brushes Independent power supply LCTU brass core + lubricant Hydraulic accumulator GE® Components Wear parts UPS ......................................................... Battery pack Yaw brake .............................................Pad - type B Pad - type A Hoses Secondary brake ............................. Brake pads - BSFH 300 Brake pads - BSFI Diaphragm accumulator ............ 0.32l Slipring gearbox ............................... Power brushes Generator .............................................Power brushes 50 to 100 mm Battery trays ...................................... Battery trays Pitch motors ...................................... Carbon brushes Module 3: Oil exchange • 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 • Inspection of the leading and trailing edge of the rotor blade as well as to the pressure and suction side on cracks, erosion, paint damage or other damages • 4-point measuring of the lightning protection system • Inspection of the lightning receptor(s) for damage caused by lightning strikes • Inspection of the glued connections of the rotor blade on air inclusions, cracking and peeling • Inspection of the rotor blade seals for cracks, structural damage and functionality • Cleaning of the drainage holes (if applicable) • Inspection of the flow elements and the leading edge protection tape (if applicable) • Detailed report including images • Repairs up to four man hours included Module 5: Unscheduled Maintenance • Remedying of all faults, requiring a call out • Including labor, expenses and all tools required • Except for damage on major components and damage caused by force majeure • Also on weekends and public holidays • Please read the *footnote for WindKeeper® Basic Modular Module 6: Maintenance of frequency converter (GE®) • As specified by manufacturer 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 WindKeeper® Complete Modular
Major components Vestas® • Rotor blades • Casting part of hub • Blade bearings • Base frame • Yaw gear ring • Gearbox • Generator • Tower • Main bearing and main shaft • 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 1 to 3 WTGs • 97 % average technical availability for 4 and 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) • Based on 12 hours of rotor blade maintenance every two years • Please read the *footnote for WindKeeper® Complete Modular
Technical availability (TA) is calculated as follows:
AE = (8.760 – MH) 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 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: Maintenance and replacement of safety components • Checking and replacement of all system components of the WTG requiring testing and monitoring as required (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) Every Vestas® V80/V90 contains rescue equipment and a service lift. The following is checked: • Ladder and climb assist system • Rescue equipment (for each WEA of 1 MW or more) • Crane • Service lift (for each WEA of 1 MW or more) • Personal equipment protecting against falling (e.g. belt, safety rope and fall absorber) • Fire extinguishers, helmet and first aid box (if applicable) Module 10 for Vestas® V52 (850 KW) The following is checked: • Ladder and climb assist system • Crane • Personal equipment protecting against falling (e.g. belt, safety rope and fall absorber) • Fire extinguishers, helmet, rescue device and first aid box (if applicable for WTG)
Module 10 for GE® A service lift is not included in this category but could be ordered as an option. Only from a certain year of manufacture onwards were WTGs with a hub height of 100 m supplied with a service lift. The following is checked: • Ladder and climb assist system • Crane • Personal equipment protecting against falling (e.g. belt, safety rope and fall absorber) • Fire extinguishers, helmet, rescue device and first aid box (if applicable for WTG) • Service lift (if WTG contains lift) Module 11: BGV A3 & SF6 check BGV A3 check: • Checking of the electrical installation • According to the requirements of BGV A3, DIN VDE 0105-100 and VDS clause 3602 • Inspection, functional testing and measuring (including measuring report) • Prompt remedying of minor faults SF6 check: • Visual inspection of SF6, checking of torques on the end seals, cleaning of connections, checking of SF6 gas and functional check of triggering relay • Including labor, expenses and all tools required for this work Module 12: Maintenance of external transformer station for GE® medium voltage switchgear (MS) • General visual inspection including checking of the MS system • Checking of all bolted contacts and switch mechanisms • Including cleaning and relubrication of drives • Trial switching including checking of 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 LV system/compensation system • General visual inspection and checking of LV system • Checking of all bolted contacts and switch mechanisms • Trial switching including checking of auxiliary switches and of 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 Others: • After completion of the maintenance work, the customer is issued a maintenance report 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 material, expenses, labor and all tools required for this 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 • 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 this work Module 13 XXL: CMS monitoring and reporting • 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
Optimization modules
14.02 Ventilation package transformer • More efficient ventilation package for transformer • Special deflectors guide the air through the nacelle • Only 20 % of the cooling air enters the transformer (sufficient for cooling) • Prevents soiling, e.g. salt deposits • Increased service life 14.03 Slipring box suction system • Accurate extraction of air from the slipring room • Automatic removal of graphite dust in air current • Minizes susceptibility to faults (increased temperatures, spark formation, flashovers, short-circuiting) • Additional call outs are no longer required • Reduces work for service engineer • Prevents damage to generator and total failure 14.04 Yaw drive monitoring • Messuring 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 14.05 Replacement of rotor cables • 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 14.06 Arc sensor • 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 14.07 Permanent lubrication system yaw gear ring • 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 GE® 14.50 Kidney filtration system of main gearbox oil • Checking of 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 • Gearbox oil can be changed less frequently (60 months+) • Additives remain dissolved in gearbox oil
• Reduces switching operations to a max. of 20-30/year (normally 2,500 to 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 14.53 Permanent lubrication system of main bearing • Continuous lubrication and supply • Independent system for each separate bearing • Prevents duplicate lubrication during maintenance • Low wear • Prevents excessive and insufficient lubrication • Increases the service life of the main bearings 14.54 Permanent lubrication system of generator bearing • Continuous lubrication/supply of fast running generator bearing • Independent system for each separate bearing • Prevents duplicate lubrication during maintenance • Low wear • Prevents excessive and insufficient lubrication • Increases the service life of the generator bearings 14.55 Permanent lubrication system of yaw gear • Continuous 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
15.04 Examination of foundations 1. Examination of concrete foundations and reinforcement (Ground Penetration Radar) 2. Examination of mounting piece (UT Phased Array Technology Module 15: WTG check – GE® • To be checked approx. every 12 month on request 15.50 Diagnosis of base frame/generator support • Checking generator support for cracks (magnetic powder test) • Ultrasound and X-ray testing on request • Including documentation and photos 15.51 Repair of base frame or Live Time Service 1. One-off repair as required 2. Continuous monitoring and repair up to the end of the operating time of the WTG 15.52 Measuring of machine base frame and generator support • Measuring of machine base frame (photogrammetry) 15.53 Examination of drive train • Checking for cracks/lateral cracks on rotor shaft below the seat of the main bearing 15.54 Examination of foundation 1. Examination of concrete foundations and reinforcement (Ground Penetration Radar) 2. E xamination of mounting bracket (UT Phased Array Technology)
14.56 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 14.57 Axis cabinet ventilation • Optimum and continuous 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 14.58 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 check – Vestas® • To be checked approx. every 12 month on request 15.01 Diagnosis of generator support • Includes checking generator support for cracks (magnetic powder test) • Ultrasound and X-ray testing on request • Including documentation and photos
14.51 Position monitoring of gearbox • Permanent monitoring of position of gearbox 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
15.02 Examination of gearbox • To be checked approx. every 12 month on request special test methods for different types of gearbox in their installed state (camera and ultrasound test method) • Including documentation
14.52 Grid coupling contactor • Relieves the circuit breaker as protection element against overcurrent and undervoltage
15.03 Examination of drive train • Checking for cracks/lateral cracks on rotor shaft below the seat of the main bearing
09/2012
Module 14: Upgrades Vestas® 14.01 Carbon brush holders • New fixation concept • Even wear on leading and trailing side • Conservation of sliprings • Quick and simple replacement of carbon brushes • Safe and quick handling of installation work • 50% increase in service life of carbon brushes • Extends change intervals from 1 to 1.5 years • Lowers replacement costs