Offshore oil change - Optimise for huge cost savings

Reduced costs, minimised downtime, optimised oil changes – everyone wants it but it is not so easy to achieve in the case of offshore wind farms. The difference between condition based maintenance and planned maintenance over a 10 year period is typically EUR 40,000 – that adds up fast with a large array.

Now, instrumentation designers cmc Instruments GmbH have joined forces with offshore logistics experts Speedwind Offshore GmbH to improve efficiency and lower costs of gear oil change.

Condition-based maintenance from continuous, online monitoring by the WearSens® system from cmc Instruments provides,

• Detection of critical operating conditions
• Oil change on demand
• Damage prevention, increase turbine lifetime
• Real time information of oil condition

WearSens® is easy to install and inexpensive to retro-fit. The decentralised, web based monitoring system makes results available anywhere in the world. It can be employed as a stand-alone unit or as part of a more comprehensive condition monitoring system.

Service provider Speedwind Offshore GmbH aim to deliver best-in-class practice for the condition based maintenance of offshore wind turbines. In line with the latest Health & Safety standards they have developed the SWOC 1.0 Container System and Service Modules.

The SWOC 1.0 is a 20-foot container equipped with two, separate, special hose systems for filling the transmission and hydraulic systems. A specially developed emergency coupling prevents oil leakage and avoids pollution of the environment. To stop thermal damage, the gear oil is preheated indirectly in a closed system to about 50°C before the pumping process.

The flushing oils are collected after the cleaning procedure and separated from all abrasive- and corrosive wear particles, water and oil deposits. This leads to a cost saving for the flushing process of up to 60%.

In the past wind turbines have been compromised by vibration, particulate matter in the oil system and cracks in the roller bearings. The only technology to measure these effects had detection limits such that damage had already occurred by the time the alarm was sounded. Rigid inspection intervals, sometimes unnecessary, are costly to perform, especially on offshore sites. Change the oil or replenish additives only when necessary. Rigid maintenance intervals can be a waste of money or they can be too late. With condition based maintenance from 24/7 monitoring huge savings can be made in money and man hours whilst optimising loads and achieving better lifetimes.

Want more information? Get it here.

cmc Instruments GmbH are a design, instrumentation and engineering company based near Frankfurt with extensive knowledge in tribology, oil aging mechanisms and instrument design.

Speedwind Offshore GmbH are a service manager of offshore vessels and maintenance. They can provide a one stop shop for contacts to suppliers, classification bodies and professional links.