How Acoem's early detection helped avoid 100k+ repairs on a Wind Turbine

Country: France
Application: Wind Energy

EXECUTIVE SUMMARY

By leveraging Acoem’s MV-x continuous monitoring system, Acoem MCT™ and Advisor services, a wind farm operator avoided a costly damage initiated by a misalignment failure. A sudden spike in vibration levels on one of the monitored wind turbines alerted Acoem Advisor experts, prompting an immediate inspection. The issue: a fatigued coupling disk, identified and repaired before it could cause prolonged downtime.

The Challenge

One of the 24 wind turbines of this farm monitored by Acoem showed a rapid increase in global vibration levels, particularly on the generator sensors. If left unaddressed, this issue could have led to severe coupling failure, extended downtime, and substantial repair costs. Additionally, poor alignment could have further exacerbated mechanical stress, increasing wear on critical components and reducing the turbine’s operational lifespan.

The Solution

Continuous Monitoring with MV-x: Acoem’s MV-x system detected abnormal vibrations in real-time, allowing for immediate action.
Acoem MCT™ tracks machine operating condition in real time in order to automatically adjust the monitoring strategy and obtain repeatable measurements making trend analysis more reliable on variable operating processes
Advisor Expert Analysis: Acoem’s analysts provided precise recommendations, urging the operator to inspect the coupling and generator foot bolts

The Results

Rapid detection and intervention prevented a critical failure.
Reduced downtime: The turbine was repaired and realigned swiftly, avoiding prolonged shutdown.
Cost savings: Preventing a full breakdown of the turbine saved the operator an estimated €100,000 in potential repair and maintenance costs. Early intervention and realignment not only avoided the immediate expense of replacing the coupling disk but also extended the operational lifespan of the turbine, reducing future downtime and repair risks.

The Impact

Beyond resolving the immediate issue, Acoem’s intervention reinforced the value of continuous monitoring and precision alignment in wind turbine maintenance. By demonstrating its expertise and responsiveness, Acoem strengthened its partnership with the wind farm operator, positioning itself as a trusted advisor for long-term reliability solutions.

Many costly wind turbine failures find their route cause in a misalignment issue.

Learn more about the importance of shaft alignment and dedicated Acoem solutions here.