8 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Online Oil Condition Monitoring for Wind Turbines By Steffen D. Nyman, Corporate Trainer, C.C.JENSEN & Noria Partner Introduction Clean oil is still in focus here in 2021 - especially within the wind turbine industry. Oil analysis are often used to predict failure, but the oil analysis only show the status at the specific time of the sample, and it is difficult to ensure the sample is completely representative, since the oil cleanliness varies hugely according to machine load, idle or standstill. The cleanliness of the sample bottle and the handling also plays a large role. Furthermore, 6 to 12 months between oil sampling is normal, and during this period, a lot can happen. This article will cover early diagnosis using online monitoring. We will also discuss a study showing the benefits of offline oil filters on wind turbine gear boxes. CJC Fine Filter 27/27 with CJC Oil Contamination Monitor OCM 15 Online oil monitoring Online oil sensors are becoming increasingly popular, and the best systems are considering oil condition, water content and particle count as well as machine load in combination. Particles are always being created during machine operation, depending on load, rotational speed, oil temperature etc., but if the oil is kept mostly free from contaminants, then wear will be reduced to a minimum. sent via a secure connection (GSM, WIFI or Ethernet) to a cloud based solution for further analysis. Alarms will be sent to the operator when pre-set limits are surpassed (T2render Basic) or when the individual system oil and equipment trend varies from normal operation (T2render Pro). Study - Monitoring particles on WT gearbox Condition Monitoring Unit with sensors. Source: C.C.JENSEN Cloud-based user interface One of the available web-based platforms for online monitoring is the CJC T2render, which receives data from the CJC CMU, Condition Monitoring Unit, incorporating different sensors. The encrypted data are This Danish wind park was erected in 2013 consisting of Siemens-Gamesa wind turbines, all larger than 3 MW output. The gearboxes were installed with CJC 3 micron offline oil filters right from the initial start-up, so the oil has been maintained clean throughout the 8 years in operation. In 2021 a study was caried out by the Durham University, UK in corporation with the Danish operator of the wind farm. The purpose was to study particle contamination in the gear oil using online particle counters. During operation of a gear box any changes in load, start/stop, temperature or other stress factors, will create particles which are visible as a particle peaks on the online counter. But how many percent of the total particle amount, do these peaks account for? Illustration 2 shows 4μm particle peaks correlating with wind turbine stop/start as well as changes in wind speed/power output. Source: Durham University Since the gear oil is continuously filtered with the 3 micron offline filter, the base line for particles is quite low under normal operation, which are shown as the green area in illustration 3 (below). Illustration 3 clearly shows the 4 micron particle peaks above the low ISO code at normal operation of the gear. Source: Durham University In this study it was calculated how many percent the particle peaks represent in the four different wind turbine gear boxes. It verifies that peaks do account for a large percentage of the total amount of particles: in fact 50-80 percent ! It is therefore utmost important to ensure that additional particles being created during stress/load changes, are removed as quickly as possible, to limit the time in which they can do damage to gears, pumps, bearings with ultra-thin oil film clearances below 3 micron. When wedged between moving surfaces, one particle can easily create hundreds of particles, resulting in severe wear. The CJC Offline Oil Filter is operating continuously with a very stable and consistence filtration efficiency, which will keep the oil clean. This is one of the reasons why CJC filters are the primary choice of OEMs, resulting in more than 135,000 CJC offline filters installed worldwide on with turbines. Special thanks to Dr. Richard J. Williams, Assistant Professor (Research) at Durham University, as well the support of EPSRC Prosperity Partnership: A New Partnership in Offshore Wind, grant number EP/R004900/1. 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However, renewables still have some way to go before they overtake fossil fuels such as oil and n COMMERCIAL CONTENT DANISH QUALITY WIND MAGAZINE A wide range of premium oils and greases coupled with data-driven maintenance analytics and services help ensure success in wind energy. Photos: Castrol Castrol takes a 360-degree approach to ensure smooth-running wind industry Castrols 360 soluti 6 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Photos & illustrations: Expo-net EXPO-NET resin flow mesh products save time and cost for wind turbine blade manufacturers By Nigel ODea Specialist wind energy rotor blade producers and original equipment manufacturers (OEMs) have discovered the DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Teknos to launch robot applied Teknoblade LEP solution in early 2022 Teknos launches a new single-layer maintenance coating for application by robots. The demand for more sustainable coatings is increasing in the wind industry. BY KARIN JENSEN Tekno 8 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Online Oil Condition Monitoring for Wind Turbines By Steffen D. Nyman, Corporate Trainer, C.C.JENSEN & Noria Partner Introduction Clean oil is still in focus here in 2021 - especially within the wind turbine industry. Oil analysis are often used t DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Illustration 2. 4μm particle peaks correlating with wind turbine stop/start as well as changes in wind speed/power output. Source: Durham University Illustration 3. The 4 micron particle peaks above the low ISO code at normal operation of the gear. 10 DANISH QUALITY WIND MAGAZINE COMMERCIAL CONTENT Deck1 to disrupt the offshore wind industry with digital trading and operations platform Deck1 is developing a digital platform that incorporates all aspects of the supply chain. 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