PDF follows on 23.09.2014

VESTAS®
Much to discover.
Services and upgrades for your Vestas® V47, V52, V66, V80 and V90 WTGs.
WE LISTEN.
Contents
Page
Aluminium ring examination04
Generator support diagnosis05
BGV A3 inspection07
Generator 2 MW07
Main bearing examination08
Internal crane system08
Ventilation package transformer11
Carbon brush package11
LED beacon light12
Arc sensor13
Permanent lubrication system (yaw gear rings)14
Replacement of rotor cables15
Slip-ring box suction system17
Reinforced transformer bracket17
Yaw drive monitoring system18
Access monitoring18
‘Vestas’ is a registered trademark of Vestas Wind Systems A/S, Denmark.
03
"We are very familiar with turbines
from the far north."
Denmark is the home of the small, brightly-coloured plastic bricks from which can seemingly
be used to build almost everything. Thanks to the Vestas® wind turbine generators (WTGs), a
foundation stone of wind energy was laid in the far north. Those bright little plastic bricks and
the already mentioned WTGs have something else in common: sometimes you have to fiddle
about for a while until you get the perfect result.
But with a bit of imagination and even more experience you can always find a solution.
With WTGs, my six years of experience at Vestas® alone don't help me. Above all, my team does.
Together, we are developing our own upgrades and other solutions for WTGs by the Danish
manufacturer at our competence centre in Hamburg.
And, of course, they are aligned towards the needs of our customers – as with every other
turbine type supported by us. You will be staggered to discover how reliably older Vestas® V47,
V52, V66, V80 and V90 turbines can generate good yields after many years. This is outlined more
precisely in the examples on the following pages.
You can get even more precise and, above all, a personal service by phoning us. I would,
therefore, very much like to recommend my colleague and Global Sales Manager Michael
Richter as your expert contact when it comes to solutions and contract concepts. Details of
how to contact him can be found on the back of this brochure.
Kind regards,
Olaf Kleesch
(Director Global Technical Support and Engineering)
04
Aluminium ring examination.
Problem:
The rotor blades of wind turbine generators (WTGs) are
subject to enormous loads during operation. As the rotor
blades are held in place by an aluminium ring, these also
have to carry great forces.
This great stress can lead to machine fatigue and therefore
cracking. If these damages aren't discovered ahead of
time, in the worst case, a blade could even break off.
Solution:
Together with the experts at WPT-Nord GmbH, Availon
has many years of experience and expertise in the area of
non-destructive material testing at its disposal. This allows
possible sources of danger to be determined ahead of
time and, if necessary, resolved. All this whilst upholding
nationally and internationally recognised certifications.
Overview of benefits and features of aluminium ring examinations:
•Maintains WTG’s operational reliability
•Inspection and diagnosis of aluminium rings and damage repair
•Certified repair procedure without having to remove the blades
•Short downtimes
•Non-destructive material testing
•Ultrasound and dye penetration testing
•Damage repair via welding procedure in accordance with DIN EN ISO 14175 I1
•Prevention and/or delay of recurrent crack formation in components under dynamic loads
•Lifetime service concepts
•For V47 turbines
05
Generator support diagnosis.
Problem:
Over the lifetime of a WTG, enormous mechanical loads
act upon its components. The seams of welded generator
supports represent a weak point in this. Similarly to
welded base frames, abnormalities were detected in the
weld seam connections. What begins slowly, can, if left
undiscovered, end in long downtimes and high costs.
Solution:
As with the aluminium ring examination, Availon can also
rely on the many years of experience and the knowledge
of the WPT-Nord experts in this case. A magnetic pulse
process is used to non-destructively examine 30 or, if
necessary, more test areas and determine whether cracks
have occurred and, if so, where. Of course, nationally and
internationally recognised certifications are upheld.
Overview of benefits and features of diagnosis of generator support:
•Maintains WTG’s operational reliability
•Inspection and diagnosis of generator support and damage repair
•Non-destructively material testing using a magnetic pulse process
•Abolition of cracks using MAG, E and WIG welding procedures
•Prevention and/or delay of recurrent crack formation in
components under dynamic loads
•For V66, V80 and V90 turbines
06
3
4
1 2
12
ge
nach p r ü f t
BGV
A3
Näc
h
Prüf ster
te r m
in
1
Problem:
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.
3
14
15 1 6
07
8
0 11 1
9 1
2
BGV A3 check.*
5 6 7
17
Solution:
Together with ABO Wind, Availon has developed the
first BGV A3 testing especially for WTGs. Taking into
account the various WTG types, every use follows its own,
turbine-specific plan. Over 150 measurement points
and kilometres of cables are responsibly tested, taking into
account all legal requirements.
Overview of benefits and features of BGV A3 testing:
•Upholds the safety of the electrical equipment in WTGs
•According to the requirements of BGV A3, DIN VDE 0105-100 and VDS clause 3602
•Avoids accidents with serious consequences due to electrical faults
•Reduces the liability risk for operators
•First BGV A3 testing process especially for WTGs
•Seamless documentation including detailed description and, if necessary, photos
•Implementation recommended every four years, for mobile devices: annually
Generator 2 MW.
Problem:
Over the course of a WTG's service life, turbine damages
can occur from time to time that affect major components.
For example, the generator. Alongside unwanted turbine
downtimes and yield losses, in the worst case scenario, this
can lead to the total failure of the entire major component.
Overview of benefits and features of the
Generator 2 MW:
• Compatible with generators of other manufacturers
•High speed variability
•Consistent output for many years
•High thermal loading capacity
•Optimised effectiveness
•Efficient cooling system
•For V66 VCS®, V80 and V90 2.0 turbines
Performance exclusively applies to Germany and is based on German legal principles and guidelines.
* Solution:
The Generator 2 MW is a joint development. The optimised
effectiveness is just one of many advantages. Alongside
high speed variability, this also includes manufacturerindependent compatibility. Furthermore, the design of the
Generator 2 MW according to heating class F also leads
to an extended service life.
08
Main bearing examination.
Problem:
As the main bearing housings are subject to major loads
in WTGs, cracks are often formed in this area. This is
probably down to too much stress. And this problem
occurs more often than you might think: crack formations
were observed in 80 out of 100 turbines examined. If
these damages are not recognised ahead of time, high costs
and long downtimes are often the consequence.
Solution:
In this case, Availon can once again rely on the expertise
and many years of experience of WPT-Nord. The experts
for non-destructive material testing have the know-how
required to determine determine possible sources of
danger in and around the main bearing and, if necessary,
to rectify them. This allows the quality of the main bearing
to be secured for the long term. As usual whilst upholding
nationally and internationally recognised certifications.
Overview of benefits and features of main bearing examinations:
•Maintains WTG’s operational reliability
•Inspection and diagnosis of main bearing and damage repair
•Non-destructive material testing
•Application of proven magnetic particle testing
•Radii relieve small cracks
•Prevention and/or delay of recurrent crack formation
•For V80 and V90 turbines
Internal crane system.
Problem:
The replacement of major components is a major problem
and often requires a major device such as a heavy-duty
crane. But this alone weighs 200 tonnes. Alongside the
already faulty major component, this creates many other
problems. Is there a sufficient access route to the WTG?
Will the weather allow for the use of a heavy crane?
And is a crane even available?
Solution:
The internal crane system developed by Availon means
these problems are quickly forgotten. And is also an elegant
and cost-effective solution. The system uses the internal
crane runway of the WTG. Using a variably adjustable
traverse, various large components or generator types
can be carried. These are then transported directly to the
machine house for installation, in virtually any weather
conditions. This saves time, costs and organisational efforts
caused by heavy-duty cranes.
Overview of benefits and features of the internal crane system:
•Mobile system weighing just 200 kg for fast and quick use
•Renders use of heavy-duty cranes, high in time, costs and organisational efforts, redundant
•Avoids unnecessary maintenance periods and turbine downtimes
•Almost independently usable in all weather conditions
(generators or similar are lowered or lifted through the floor of the machine house)
•No special access route or crane footprint is necessary
•Small crane (low-cost and quickly available) for the loading of replacement components is sufficient
•For V66, V80 VCS® and V90 2.0 MW turbines
03
09
10
11
Ventilation package transformer.
Problem:
A constant supply of air into the machine house is essential for
cooling the transformer. However, if unregulated, this can lead
to a number of problems. As air previously entered 100% in the
transformer box, there was significant soiling, such as salt deposits.
In the worse case, transformers had to be replaced every two years
as a result.
Solution:
Availon has developed its own ventilation
concept that ensures cooling with minimal
air supply. The special conveying system
requires 80% less air in order to 100% cool
the transformer.
Overview of benefits and features of the transformer ventilation package:
•More efficient ventilation for the transformer: special conveying system guarantees
100% cooling with 20% air
•Prevents soiling, e.g. salt deposits
•Ideal for WTGs in extreme locations, e.g. near the coast
•Increased service life of the transformer
•For transformers of V66, V80 VCS® and V90 2.0 MW WTGs
Carbon brush package.
Problem:
The erosion of carbon brushes is a normal wear and
therefore a continuous cost factor.
Wear can increase due to uneven contact pressure of
the mount. This leads to a more frequent replacement
of carbon brushes and therefore to longer turbine
downtimes.
Solution:
The carbon brush package by Availon combines an
optimised mount design with the latest carbon brush
technology. The developed mount leads to a more even
wear and therefore significantly increases the service
life of carbon brushes! Carbon brush replacement can also
take place quickly and easily in just a few minutes.
Overview of benefits and features of
the carbon brush package:
•New mounting concept with innovative new
hybrid carbon brushes
•Even wear on leading and trailing side
•Preserves the slip rings
•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
•Lowers replacement costs
•For V52, V66, V80 VCS® and V90 2.0 MW turbines
12
LED beacon light.
Problem:
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 from a total height of
100 m. The beacon light plays an important role in this,
but is exposed to adverse weather conditions.
Solution:
Availon has a tested LED beacon light system for WTGs on
offer. 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 provided
•Highly efficient LED system
•Minimal maintenance and wear
•Hard-wearing, even in adverse weather conditions
•Increases the safety of the WTG
•For V80 and V90 turbines
13
Arc sensor.
Problem:
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 recognised by the two
available arc sensors.
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 V66, V80 VCS® and V90 2.0 MW turbines
Solution:
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.
14
Permanent lubrication system
(yaw gear rings).
Problem:
Maintenance of the yaw gear is very laborious. Particularly
if the yaw pinion is lubricated manually, as even
experienced service engineers cannot guarantee an
even lubrication film. This can result in excess grease and
have a negative effect on wear and corrosive protection.
Solution:
The central lubricant pump with a grease container and
lubrication pinion guarantees a perfectly even lubrication film
and thereby ensures better corrosive 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:
•Constant lubrication of yaw pinions and gear teeth
•Avoidance of excess grease
•Prevents corrosion and wear
•Permanent, even lubrication film on gears
•Increases operational reliability
•Reduces maintenance and repair costs
•The grease container has to be replaced just once per year
•For V80 2.0 and V90 2.0 turbines
15
Replacement of rotor cables.
Problem:
A lot of wind also always means a high load for the
components of a WTG. For some, it is too high and leads
to downtimes. The analysis of downtime data shows
that many of the downtimes occur at rated output. For
example, overheating in the area of the rotor cables of
the generator. The consequences are irreversible damage
and therefore potential extra downtimes.
Solution:
Availon has developed the latest generation of rotor cable.
It has an increased cross-section and therefore also makes
a high load at very windy times possible. The suitable
developed tools and work processes also allow an especially
efficient replacement of the cable directly inside the
nacelle – without the use of a crane.
Overview of benefits and features of
the rotor cable replacement:
•Avoidance of overheating in the area of the rotor cables
•Higher loading capacity
•Cost-efficient replacement directly in the WTG
without the use of a crane
•Latest cable generation with increased cable cross-section
•For V80 VCS® 2.0 turbines
16
17
Slip–ring box suction system.
Problem:
The graphite dust created due to the erosion of the carbon
brushes accumulates in the slip-ring box. It often stays there and
causes higher temperatures, forms sparks or flashovers in the
slip-ring box that can lead to the total failure of the generator.
Solution:
The air is accurately extracted from the slipring box and the graphite dust is thereby
automatically removed from the air current.
Overview of benefits and features of slip-ring box suction system:
•Accurate extraction of air from the slip-ring box
•Automatic removal of graphite dust in air current
•Minimizes susceptibility to faults caused by increased temperatures,
spark formation, flashovers, short-circuiting
•Reduces work for service engineer
•Prevents damage to generator and total failure
•For V66, V80 VCS® and V90 2.0 MW turbines
Reinforced transformer bracket.
Problem:
In spite of its mass totalling five tonnes, the transformer
can move around a lot. It is subject to high levels of
vibration due to its rear position in the nacelle, which the
transformer bracket cannot always withstand. If a break
occurs on the transformer bracket, the transformer can
tip over or hang on one side.
Overview of benefits and features of
reinforcing the transformer bracket:
•Increase of loading capacity
•Avoidance of the write-off of a transformer
•Permanent stabilisation of the transformer console
against swaying
•Optimum use of the bearing capacity and stability of
the crane runway
•For V66, V80 VCS® and V90 2.0 MW turbines
Solution:
The stability of the transformer console can be increased.
This occurs alongside the general reinforcements, above
all, with the otherwise unused bearing capacity of the
crane runway. The console is reinforced using steel rods via
a cross joint to the crane runway. This allows swaying to
be avoided and the five tonnes of the transformer do not
cause any serious problems.
18
Yaw drive monitoring system.
Problem:
Even though it seems that all yaw motors were working
without a problem, the WTG suddenly comes to a halt.
Each actuator has failed in a very short period, one after
the other, in a chain reaction. The reason for this, alongside
high loads at the location of the WTG, is often a failure of
the friction brakes in the actuators.
Solution:
The solution developed by Availon is based on monitoring
of the current draw of the individual drive motors. Here,
the load current of the respective actuator is compared
with its idle current. If deviations from normal operation
become apparent, they can be immediately sent to the
turbine control, the operator and remote monitoring as a
fault notification via GSM module.
Overview of benefits and features of yaw drive monitoring:
•Avoids unscheduled downtimes and expensive repairs
•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 production disruptions
•Minimum loss of yield
•For V80 VCS® and V90 2.0 MW turbines – MK 1 to MK 5 class
Access monitoring.
Problem:
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.
Solution:
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 (optional: monitoring camera)
• Prevents damage, downtimes and yield cuts
• Can also be used for transformer or transfer stations
19
Godda
and
9
hello t
here!
My name is Michael Richter. I don't speak Danish, but I understand Danish wind turbine
generators very well. Just like my colleague Olaf Kleesch, who greeted you on the first
page of this brochure. Thank you for taking the time to look at our solutions for Vestas® WTGs.
In turn, I would be happy to take the time to work with you to determine which contract
concept makes sense for your WTG and how you can benefit from it.
I look forward to your call.
All the best,
Manager Global Sales
[email protected]
-532
Phone +49 (0) 40 181313
8
090
878
173
Mobile +49 (0)
Availon GmbH | Jacksonring 2 | 48429 Rheine | Germany | www.availon.eu
09/2014
Michael Richter
Michael Richter

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