Condition Monitoring System

The perfect combination of practical experience and the latest technology for reliable maintenance

When selecting the right system for a wind park, above all economic efficiency should by a key criterion. Statistical wind data, the power curve of the turbine and investment costs all form part of this calculation. But the reliability of the turbine also has a major influence on the annual yield. In order to further increase the technical availability of our machines, all wind turbines can be equipped with an integrated Condition Monitoring System as of 1.1.2003. The early warning system offers an overall, secure solution for avoiding unforeseen downtimes resulting from component wear. A Condition Monitoring System thus supports the high level of availability of the turbines and trouble-free operation.

Worldwide round-the-clock accessibility, 24-hour remote monitoring and service, rapid reaction and the use of a Condition Monitoring System are the four mainstays for the efficient and continuous operation of wind turbines.

The Condition Monitoring System

The automatic solution represented by a Condition Monitoring System is an additional instrument within the Nordex service and maintenance concept. The status of all components subject to wear, such as the gearbox, bearings and generator, are permanently monitored and archived on the basis of the acoustic frequencies measured. The system automatically draws up a comparison of the ideal and actual situation and in the event of a discrepancy signals a preventive service operation to be planned before any damage is done. In this way it is possible to significantly reduce unforeseen downtimes resulting from wear or damage to components.

The advantage:

Service operations can be planned in advance, meaning that they do not constitute a reaction to damage done but are implemented actively in good time before a breakdown can occur,
Total breakdowns and consequential damage to components are avoided
As Nordex is able to order and provide spare parts, components, cranes and vehicles in good time, maintenance work on site is shortened,
The date and time for exchanging a component can therefore be arranged in such a way that it falls at a time of the year when winds are not so high,
Inspection cycles can be extended.

The Condition Monitoring Systems, tried and tested over years

draw on drive, service and diagnostic experience with wind turbines,
provide diagnostic hardware tailor-made for wind turbines and suitable sensors,
have measuring and analysis software in line with standard browser technology,
work independently,
automatically forward alarms,
facilitate remote data transfer by e-mail and a telediagnostics service.

In addition to this, all data are archived at Nordex as histories. These data act both as documentation for customers and evidence for insurance companies.

Each Condition Monitoring System is integrated in the turbines as a stand-alone solution. The systems are completely disconnected from the visualization and control software of the turbines and work completely independently.

How does a Condition Monitoring System work?

The principle of the Condition Monitoring System is based on the recording of structure-borne vibrations caused, for example, by bearings and gear toothing. The signals are received by means of special acceleration sensors attached to defined measuring points on the individual drive train components.

In a three-month start-up phase an individual vibration picture is drawn, the so-called "fingerprint" for the turbine and its components. The values measured are stored as parameters in a "black box". When the turbine is in operation the actual values measured are automatically compared online by means of measuring routines and measuring methods, such as frequency, envelope and order analysis, with the reference values stored in the system. If there are discrepancies or limits are exceeded, the system automatically sends a warning or alarm message to the central Nordex remote monitoring center. There it is possible to draw accurate conclusions on the degree of change or wear on the basis of experience gained over years and to initiate service activities in good time.

Concerning status and reliability-oriented maintenance

All data recorded by the Condition Monitoring System of each wind turbine are evaluated in a database in the central Nordex remote monitoring center and stored there for the plant history**. In this way the historical data on individual turbine types and product families are evaluated in addition to the values of the individual turbines. The continuous growth of know-how at Nordex on the "behavior" of the components of the different machine types and/or power classes thus offers the possibility of long-term reliability-oriented maintenance.

Our service at a glance

Planning and installation of the Condition Monitoring System
Round-the-clock remote monitoring
Archiving of all turbine data in a central database
Support in the form of expert knowledge
Optimal service and diagnostics by our trained service staff
Teleservice with half-yearly reporting *

* separate teleservice-contract included in B contract

You can download a PDF about Nordex Service and Condition Monitoring.

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