Date: 2013-08-19

Schaeffler provides online condition monitoring of turbines at Crystal Rig wind farm

Schaeffler’s FAG WiPro s is an online condition monitoring system that is suitable for the permanent monitoring of wind turbines. The system is extremely compact, with the monitoring unit and multiplexer integrated in a single unit, which offers a high degree of flexibility for end users.


The system combines all control modules into a single compact housing, which measures just 260 x 150 x 90mm, enabling easy installation in control cabinets. The integrated multiplexer enables the recording of signals from up to eight different sensors.


FAG WiPro s monitors vibration conditions, which if left undetected, can cause costly unplanned shutdowns of wind turbines. These conditions include damage to bearings and gears, as well as shaft misalignments. If a specified threshold value or alarm limit is exceeded, the system triggers an alarm. The vibration monitoring data can be analysed directly on site at the central control station or this data can be retrieved via a TCP/IP communications link and analysed by either the end user or by Schaeffler. Integration of oil quality (particles) as part of the monitoring is also possible.


“On each of the five wind turbines being monitored at Crystal Rig wind farm, we’ve installed six vibration acceleration sensors,” stated Dr Steve Lacey, Engineering Manager at Schaeffler UK. “One of these sensors is a special, low frequency vibration sensor that monitors the main rotor bearing and there is also a low frequency vibration sensor on the input shaft to the gearbox. Two additional standard vibration acceleration sensors are installed on the power train gearbox, with a further two vibration sensors on the generators. These sensors provide us with 24/7 vibration data – including both time-based and frequency-based vibration data – which enables us to look for faults or to detect problems early.”


“Since the condition monitoring systems were installed in May, we’ve picked up a couple of faults in the generator bearings and identified early problems with some gears on a planetary gearbox. These faults were confirmed by Fred.Olsen by using fibre optic cameras [endoscopes] to look inside the gearbox,” he added.

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