Enhancing Wind Turbine Reliability with ACOEM’s Shock Finder™ and MCT™

Country: France
Application: Wind Energy

EXECUTIVE SUMMARY

A wind farm improved the reliability of its turbine drivetrain by implementing condition monitoring with ACOEM MV-x system, combining both Shock Finder™ algorithm and ACOEM’s MCT™ (Machine Condition Tracking) methodology. This integrated solution was specifically applied to the low-speed shafts of the gearbox, where the conditions are repetitive and predictable. The system detected early bearing defects, monitored ongoing machine conditions, and enabled real-time insights, preventing costly repairs and minimizing production losses.

The Challenge

Before implementing ACOEM’s solutions, the customer faced recurring and costly maintenance challenges with the low-speed shafts of the turbines. As the conditions were repetitive in nature, detecting faults early on was critical to prevent further damage. However, bearing defects often went unnoticed, leading to costly gearbox replacements and prolonged downtime.

Potential Consequences:

Full gearbox replacement (costing up to €250k)
Long repair times leading to significant production loss

Impact on Business:

High operational and maintenance costs
Extended periods of unplanned downtime

The Solution

The customer implemented monitoring with Acoem MV-x, applying Shock Finder™ alongside Acoem MCT™, an integrated solution designed to proactively detect and track the health of critical machine components, specifically focusing on the low-speed shafts in the gearbox.

MV-x System: The MV-x system continuously monitors the machines using the Acoem MCT™ methodology, dynamically adapting in real time to the operating status of the turbine (wind speed, power, pitch, etc.). This ensures optimal condition-based monitoring tailored to the turbine’s actual performance conditions

Shock Finder™: This technology was configured to detect abnormal shock events, particularly at low speeds, where conditions are more predictable and repeatable. It identified early bearing faults, such as cracks in the inner and outer rings, allowing for timely maintenance before catastrophic failure occurred.

The Results

By implementing Shock Finder™ and MCT™, the customer achieved remarkable results in cost savings and operational efficiency:

Cost Savings: Reduced gearbox replacement costs from €250k to €100k, saving €150k.
Production Time Saved: Cut downtime from 10 weeks to just 3 weeks, saving 7 weeks of lost production.
Additional Damage Prevented: Managed minor repairs of €56k, preventing further damage to the gearbox.
Improved Decision Making: Real-time condition tracking with MCT™ allowed better forecasting of maintenance needs, reducing unexpected failures by taking action in advance.

The Impact

The combination of Shock Finder™ and ACOEM MCT™ not only solved the immediate maintenance challenges but also laid the foundation for a long-term partnership between ACOEM and the customer. The solution has enabled continuous monitoring and predictive maintenance, improving the overall operational efficiency of the wind turbines and ensuring the longevity of the gearboxes.