Identification of Critical Operation Conditions of Industrial Gearboxes by 24/7 Monitoring of Oil Quality, Oil Aging, and Additive Consumption

Abstract

The demand for wind energy grows at exponential rates. At the same time improving reliability, reduced operation and maintenance costs are the key priorities in wind tur-bine maintenance strategies [1]. This paper provides information about a novel online oil condition monitoring system to give a solution to the mentioned priorities. The presented sensor system enables damage prevention of the wind turbine gear-box by an advanced warning time of critical operation conditions and an enhanced oil exchange interval realized by a precise measurement of the electrical conductivity, the relative permittivity and the oil temperature. A new parameter, the WearSens® Index (WSi) is introduced. The mathematical model of the WSi combines all measured values and its gradients in one single parameter for a comprehensive monitoring to prevent wind turbines from damage. Furthermore, the WSi enables a long-term prognosis on the next oil change by 24/7 server data logging. Corrective procedures and/or maintenance can be carried out before actual damage occurs. First WSi results of an onshore wind turbine installation compared to traditional vibration monitoring are shown.