Oil Sensors for Wind Turbines

Emerging Technology Day - 2016 1

Oil Sensors for Wind Industry

ATTEN2 Advanced Monitoring Technologies


ABOUT USPRESENTED BY: EDGAR MARTINEZ

ATTEN2

Atten2 is a start-up that develops and trades advanced On-line technology for fluid monitoring,

Year of Foundation

2012Products

2Patents

4

Our solutions allow to reach a new dimension in the prediction ofmachine failures, using state-of-the-art optical technology

Measuring the quality and condition of lubricants, we have established a new insight in the machines condition based monitoring,

Implementing Advanced algorithms we transform digital data intoaccurate and effective information to assess the operational risk incritical machines, adding value to our customers’ business.

About Us

About Our Company


Start of Sensorik project

2002

About Us

Company Timeline

20092st OilHealth

Patent

2006

1st OilHealth

Prototype and Patent

2011

OilWear

Patent

Company Foundation

2012

2015

Capital Increase

2016NIR Sensor

Patent


Our technology allows to measure fluids, specially lube oil, beyond counting particles from ferric materials as the standard market does by measuring all types of pollutants, allowing us to:

• Perform root cause analysis• Measure the lube degradation• Apply advanced diagnostic algorithms

Product

Atten2 counts with a team of 7 (2+5) engineers and scientists to work in R&D:

• Optical technology• Electronic and Communication• Surface and Material Techology• Mechatronics• Tribology• Data Scentist

R&D

Atten2 adds value to its technological solution through a solid service offer based on:

• Remote monitoring and advanced diagnosis• Lab sample analysis • Training• Technical service assistance

Service

Other Partners:

About Us

Inside our Company

http://www.google.es/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=7OsWggiHzPk_FM&tbnid=yxBWhTGxTufjwM:&ved=0CAUQjRw&url=http://174.143.170.127/iucrc/publicFactSheetServlet?centerId=7&ei=e6SWU-flNYHHPPaZgegM&bvm=bv.68445247,d.ZGU&psig=AFQjCNHokXADjMphf9fpSCaeOXLzQ1FqYg&ust=1402467834724004


1. Standard purchasing process

2. Renting the device and establishing a business

based on the service

Provide Technology

1. Advanced diagnosis

2. Monthly report and alarm control.

Remote Monitoring

1. Provide data management globally

2. Provide oil sample analysis in lab globally,

supported by our Wear Check association

3. Guarantee the update of every device with the

latest firmware version

4. Based on a partnership agreement, Atten2

guarantee the quick replacement of any sensor

that has suffered any damage or failure.

Global support

Our Technology

Our Services


OUR TECHNOLOGYPRESENTED BY: ENEKO GORRITXATEGI


With this technology Atten2 has gone one step forward, developing a smart

sensor that allows a reduction in the operational risk, cost out and productivity.

Linking the machine condition to operational modes through a direct

measurement of machine wear.

Our Technology

Technological Solutions

Optical Technology

Our sensors monitor the condition and quality of fluids, through the measurement Electromagnetic

spectrum bands and involving digital image processing

Advanced Algorithms

The correlational algorithms, the advanced image processing and the shape recognition together

with the auto-diagnosis capabilities make the difference

Integration & Connectivity

Our technology is highly flexible. May be used as a Stand-alone device or integrated

within broader control system.

Connectivity: SCADA/PLC/PC,

• Bubble discrimination

• Particles size classificationISO, NAS Classification

• Root Cause through digital images analysis

• Oil Degradation and Varnish diagnosis

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4 µ

6 µ

14 µ

Warning

Alarm

LUBRICANT FAILURE

MACHINE FAILURE

Micropitting. (Hard to identify with vibration)

Bearing micropitting. (Hard to identify with vibration)

Fatigue(Hard to identify with other PdM technologies)

Cutting wear(Hard to identify with other PdM technologies)

Sliding Wear(Hard to identify with other PdM technologies)

Corrosion(Impossible to identify with vibration)

E.ON: Thanks to the early failure detection of a Gearbox the customer did a minor reparation with a cost of

$17.500 instead of a fatal failure of $522.000

OilWear allows to diagnose failures in very early stages

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Warning

Alarm

Failure startISO: 20/18/15

Cleanliness ISO Code evolution and Limit Values

Original Size: 40

R:230, G:215, B:180

Original Size: 27

R:208, G:195, B:160

Original Size: 35

R:175, G:204, B:156

Original Size: 60

R:230, G:215, B:240

Original Size: 29

R:184, G:125, B:124

Original Size: 55

R:210, G:201, B:191

Original Size: 74

R:128, G:234 B:190

Original Size: 26

R:187, G:198, B:165

Original Size: 36

R:130, G:125, B:140

Original Size: 54

R:212, G:214, B:174

Original Size: 48

R:187, G:135, B:147

Original Size: 65

R:158, G:196, B:124

Original Size: 56

R:204, G:175, B:139

Original Size: 39

R:180, G:195, B:164

Original Size: 45

R:224, G:217, B:187

Original Size: 52

R:165, G:174, B:112

SLIDING WEAR

FATIGUE

CUTTING WEAR

SLIDING WEAR SLIDING WEAR

FATIGUE

FATIGUIE

SLIDING WEARSLIDING WEAR

SLIDING WEAR

FATIGUE

FATIGUE

FATIGUIEFATIGUIE

FATIGUIE

FATIGUIE

CUTTING WEAR

Original Size: 26

R:187, G:198, B:165

CUTTING WEAR

Original Size: 26

R:187, G:198, B:165

Root Cause analysis:Automatic Particles shapes recognition and classification

Acceptance report for a

repaired wind turbine

gearbox

OilWearReal case video


Using Oil Degradation capabilities allows

Get Spectrum analysis with anadapted algorithm for every oil type

Provide the oil life(%OD: Oil Degradation index)

Provide trending about the oilevolution along time

There are different chemical processes in the lubricant oil degradation.

RULER VISCOSITYOXI (FTIR)

AN

• Additives consumption • Oxidation • Polymerization

Lubricant Oil Change optimization:

• FUCHS RENOLIN UNISYN CLP 320

• TEXACO MEROPA 320 WM

• CEPSA AEROGEAR SINT 320

• SHELL OMALA OIL 220

• SHELL OMALA OIL HD 320

• CASTROL TRIBOL 1510/320

• CASTROL OPTIGEAR BM 320

• CASTROL OPTIMOL SYNTHETIC X 320

The sensor algorithm has a list of characterized lubricants(*) This is a short list of chraracterized oils

Castrol Optimol Synthetic X320

Castrol Tribol 1510/320

MobilGear SHC XMP 320

• Klüberoil GEM 1-320N

• Klübersynth GEM 4-320N

• Klübersynth GH 6- 320

• BESLUX GEAR XP-320

• BESLUX SINCART 320 W RED

• BESLUX GEARSYNT XP-320

• MOBILGEAR SHC XMP 320

• GEARMASTER ECO 320

Fuchs Renolyn Unisyn CLP320

Texaco Meropa 320 WM

Oil Degradation

Particle Counting >4µ

Particle Counting >10µ

ISO Code 4406

Shape Recognition >20µ

Wear S120Features Wear C120 Wear P120

Image Recovery (advanced analysis)

Particle classification for type >20µ

Our Technology

Product Portfolio

Our Technology

Connectivity and Integration

CONDITION DATA (FILES .DAT)IMAGES(FILES .JPG)

WEB PLATFORM FOR INFORMATION MANAGEMENT

SENSORS

AUTOMATIC REPORT

SCHEDULED TASKS(READING FILE

.DAT y .JPG)

DATA BASE(FILE EXTRACTION.DAT)

FILE SERVER(FILE STORAGE.DAT Y .JPG)

Our Technology

Information management Web Software


Cases

HYDRAULIC SYSTEM

GEARBOX LUBRICATION

SYSTEM

SCADA - WIND TURBINE CONTROL

SYSTEM

CMS - CONDITION MONITORING

SYSTEM

On-line oil sensors provides valuable and reliable information for the wind turbine control system and CMS in order to plan O&M activities

In the Wind energy industry the average practice isto change the synthetic oil every 3-5 years.

Using OilHealth is feasible to harness the lubricant life safely, doing a narrowcontrol of oil parameters in real time.

In synthetic oil the total life cycle is estimated about 7-10 years

• A wind turbine manufacturer started to use theOilWear Sensor in 2015 at their repair shop located in Spain

• Using OilWear, they identified particles in a repaired 1,5 MW gearbox.

• The sensor allowed them to identify different kindof problems in the gearbox:

• Fatigue• Sliding wear• External contamination with fiber.

• This early diagnosis avoided a fatal failure in thegearbox, a major repair and a warranty claim.

Root Cause analysisSuccess Case

The Customer estimated the cost saving about

≈100.000 €.

As reference, the renting for two cranes required during the installation

maneuver is about 20.000 €.


Current Operation:

Total Cost Oil Change per WTG: 5,500 €/WTG

Total Cost wind farm Oil Change: 220,000 €

Oil changes along the wind farm lifecycle: 6

Total cost of oil changes

1,320,000 €

OilHealth

Cost Oil OilHealth: 2,200 €/WTG

Total Cost farm Oil Change: 220,000 €

Oil changes along the wind farm lifecycle: 2

Total cost of oil changes using OilHealth :

440,000 €

PAYBACK: 3 years or first oil change

SAVINGS: 880,000 € along the wind farm lifecycle

Wind farm with40 WTG

Power Installed: 80 MW


HAPPENSWHAT

ATTEN2 ADDING VALUE


Atten2 provides a solution oriented to reduce the operational risk, through the On-line

monitoring of the level of wear that takes place in the machine,

Risk Reduction

Certain kind of inspections such as the bearing, gearbox and shaft, may be accomplished when

the machine condition needs it, instead a calendar base strategy. As added value, the customer

will receive an on-line report about his machine condition and how the operation affects its

reliability.

Productivity

Implementing this Technology may have an impact in cost reduction by:

• Reducing oil changes,

• Reducing important failures in gearboxes and bearings

• Reducing costs in down tower maintenance

• Optimizing maintenance planning and resources

Cost Out

This technology together with operational data, may provide an in-depth information of

the machine condition and may add a new perspective about maintenance policies

A new perspective

Our Technology

Our Value Proposition


Market Analysis

Our Clients


ATTEN2 Advanced Monitoring Technologies

C/ Iñaki Goenaga, 5,20600 EibarGipuzkoa, Spain

CEO: emartinez@atten2,comTCO: egorritxategi@atten2,comSales: plopez@atten2,com

Office Phone: +34 943 206 744CEO Mobile: +34 638 711 972CTO Mobile: +34 676 069 720

Address

Contact Info

Telephone

Keep in touch with us

THANKS

Oil Sensors for Wind Turbines

Technology

Transcript of Oil Sensors for Wind Turbines