22 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT How valuable is efficient oil maintenance and online remote monitoring - on older wind turbines Despite serious gear and bearing failures, wind turbine #3 in the Elsterheide wind farm was able to feed electricity to the grid for another 18 months until the gearbox replacement had been completed.Y C.C. JENSEN T he wind farm Elsterheide was built in a former open-cast mine for lignite. The area was re-establishment due to the soft ground and high risk of landslides, but was still a restricted area. Normal mobile cranes used in wind farms were not able to access the area, so a short-term and fast gearbox replacement was not possible. It was a long process in which Eurowind A/S operator of the Elsterheide Wind Farm apart from purchasing the gearbox and the appropriate crane technology also had to coordinate the various construction companies and as well as obtaining the approval of the Saxonian mining authority. The project objective formulated by Eurowind Energy A/S for CJC: to prolong the service time of the damaged gearbox as much as possible in order to make the maintenance measures predictable and to keep the costs within the calculated budget. Planetary bearing: Test membrane filtration PB3 cat 5, damage width: approx. degree: 0,45 μm and treatment 11 rolling element. with 30 ml pentane To achieve this goal, two precautions were taken; 1) Firstly, a large additional offline filter system with extensive sensor technology was installed for remote monitoring of the oil and gear condition (pump capacity: 250 l/h, oil filtration degree: 3 μm absolute / 1 μm nominal, depth filter, filter material: 100% renewable raw materials). deteriorated from 17/16/13 to 23/20/13 (according to ISO 4406). The result of the inspection with borescope showed a very advanced wear stage with serious damage to the gearbox bearings (damage category 5). Within a short time, it would have come to a complete gearbox and turbine failure. Shortly after the installation of the additional offline oil filter on November 12th, 2014, the cumulative content of particles > 4 μm in 100 ml of oil was reduced to approx. 20,000, which corresponds to the oil cleanliness of ISO Code 15. Oil analysis by an independent laboratory confirmed an oil cleanliness level of 14/13/9 (according to ISO 4406) in January 2015. 2) Secondly, the nominal output of 2 MW was limited to 1.5 MW in order to simultaneously reduce the load on the gearbox and to reduce further material damage. Measurements show that especially particles < 5 μm have a particularly harmful effect on system components. Re-circulation of particles in the oil system generate more particles and results in a chain reaction of wear. The finer the oil filtration, the longer the service time of the gearbox, bearings and components. The additional offline oil filter system regulated the particle content and reduced the occurrence of further wear. In June/July 2015, when the sensor technology was integrated with the oil filter and connected to the monitoring software Trender Tool, a new sudden increase in particle content was detected, which resulted in an alert to the operator at Eurowind Energy A/S. Depending on the severity code of the particle load, different alerts occur (good, warning, critical). In this case, the increase in particle content was classified as abnormal wear and the development of the oil and gearbox condition was categorized as very critical. The design of the oil filter was deliberately oversized in order to get the enormous amount of abrasive wear particles under control and to ensure optimum oil cleanliness. By removing particles, oil degradation products, water and acidity, the highest oil cleanliness was achieved, so that further oil related wear was prevented. In addition, the transmission of data for the exact oil condition values make it possible to detect abnormal gearbox wear at an early stage, so that intervention can be timely, cost-effective and predictable if necessary. The background story In August 2014, based on the biannual oil analyses, it was detected that there was a significant amount of particles being generated. Within 6 months (February to August 2014), the cumulative content of particles > 4 μm increased 47-fold to more than 6 million particles in 100 ml of oil. The cleanliness rating Enlargement of test membrane showed contamination with brass, copper and iron particles from < 1 μm to > 300 μm (component wear) as well as oil degradation products (black deposits < 5 μm) Oil analysis of August 22nd, 2014: BEFORE installation of the additional offline oil filter system Oil cleanliness class: 23/20/13 (according to ISO 4406) WIND DANI S H QUALIT Y Commercial Content MAGAZINE N OVEMBER 2019 Danish Quality page 4 Huge special transports page 10-11 Harbour Logistics page 7 & 12 NMInsights. 2 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Welcome to the Danish Quality Wind Magazine W e take this opportunity to salute the Danish Wind industry because it is the birthplace of modern wind energy as we know it. From humble beginnings in the mid- and west of Jutland in the beginning of DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT From small components to 600-ton steel structures For more than 20 years, East Metal A / S has supplied high-quality components and steel structures to leading wind turbine manufacturers. Thoroughness is the hallmark of the company from West Jutland 4 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Danish Quality: from the start a leading country in wind energy The wind industry was born in Denmark. From the development of one of the first electricity-generating turbines to the production of the world's first multi-megawatt wind turbine, th DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT SMEDEGAARDEN A/S Est. 1962 Recycling within the offshore industry We buy and sell machinery and goods for the offshore and maritime business. www.smedegaarden.net Smedegaarden A/S Vikingkaj 5 6700 Esbjerg Tlf. 75 12 88 88 5 6 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Fully automatic, robot-controlled coating of towers inside and outside at the same time. ABOUT VALMONT SM Established in the 1940s, Valmont SM handles the production, assembly, and maintenance of powerful and complex steel structures for many dif DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Offshore focus in line with the harbor's DNA Founded as a fishing port in 1914, Thyboron Port has since evolved into a ABOUT THYBORON PORT multifunctional and modern commercial port, which in recent years has Thyboron Port is a municipal self-gov 8 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Leading the offshore future Offshore wind is projected to be a trillion-dollar industry by 2040, according to the IEA. Denmark, the birthplace of offshore wind, is well-positioned to be at the forefront of this bright future. BY ANTHONY LIBERTO DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Pioneers in the wind industry with a wealth of off shore wind experience Unparalleled experience, a personal touch, and in-depth knowledge are the hallmarks of EMD International A/S, which provides services in the area of wind energy consulting thro 10 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT When the worlds longest turbine blade crossed the Atlantic DSV took on the job of shipping the worlds longest turbine blade from Europe to the US. With a successful, safe and on-time delivery, DSV won the respect of the industry along with lot o DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT 11 Transport isnt a last-minute decision Planning the transport of extremely heavy cargo takes a long time, and global transport and logistics company DSV likes being brought in at a very early stage when an offshore operation is under construction. 12 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Port of Roenne is the pre-assembly port of the Kriegers Flak-wind farm projekt Bornholm has grown. The island has grown to 150.000 square meters as a result of a new construction at Port of Roenne in the Baltic Sea, where quays now have a carryin DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT 13 ABOUT ELTRONIC WIND SOLUTIONS Secure handling and support throughout the lifespan of a wind turbine An innovative and holistic approach to the wind turbine industry makes Eltronic Wind Solutions a value-adding partner, which is widely used in pr 14 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT A quick coating that protects and prolongs the life of a turbine Offshore repairs are never easy. But Teknos unique coating cures fast, applies quick and is very durable. Altogether, it reduces the number of repairs, the time of the repair and t COMMERCIAL CONTENT DANISH QUALITY WIND MAGAZINE 15 16 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Skagen Blade Technology is working hard to live up to the UN's Sustainable Development Goals, which is why all employees are dressed in sustainable workwear developed in the sister company TOIL 'N' MOIL. Specialists from Jutland keep the world's DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT 17 Special scaffolding based on knowledge and consultation Competent and highly qualified employees are the cornerstone of O.G. Specialstilladser ApS, which supplies tailor-made scaffolding solutions to the industry. The company meets the demands an 18 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT The foundation for wind farms of the future As a result of the escalating climate debate, the global market for offshore wind turbines is booming. Universal Foundation contributes to sustainable development with its Mono Bucket foundation - an in DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT 19 The key to reliable wind turbines I n the wind industry, there is a focus on how to maximize the capacity of the wind turbine with minimal use of material. Wind turbines must withstand enormous loads and forces, and this puts higher demands on 20 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Rental PPE will save you time, money and green conscious Renting PPE offers companies a hassle free solution. HeliPPE handles maintenance, service and keeping track of their rental PPE and a review after each use ensures that the standards and DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT OFFSHORE MAGAZINE we are all about Energy at sea Magazine Nuts Bolts and Brains of the Worlds biggest wind farm page 4 ORE H S F F O om sinet maga nr 1 2017 i til søs energ Huge opportunities in decommissioning page 10 nr. 2 Margins Matter S 22 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT How valuable is efficient oil maintenance and online remote monitoring - on older wind turbines Despite serious gear and bearing failures, wind turbine #3 in the Elsterheide wind farm was able to feed electricity to the grid for another 18 months DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT 23 Oil analysis of January 28th, 2015: AFTER installation of the offline oil filter system Oil cleanliness class: 14/13/9 (according to ISO 4406) After solving this incident, the wind turbine was in operation for another 9 months at 1.5 MW and prod NMInsights.