Tan Delta Systems, a manufacturer of real-time oil quality monitoring sensors and systems, is leading the way within the wind turbine sector with the launch of SENSE-2. The new oil condition monitoring kit provides real-time data about machine oil quality to optimise maintenance and reduce operating costs.
The SENSE-2 is plug-and-play and accurately identifies when oil reaches the end of its life, superseding traditional time-based maintenance schedules which can result in oil being discarded prematurely with the potential of wasting up to 50 per cent of its useful life.
For the wind power industry, SENSE-2 reduces operating costs, increases power output and extends maintenance intervals by monitoring equipment condition in real-time. Operating costs typically account for 65 per cent of the total lifetime cost of a wind turbine and of this, 40 per cent arise due to unscheduled maintenance and failures so even a small reduction in operating costs will deliver a substantial increase in lifetime profitability.
As the demand for sustainable energy sources continues to increase, the efficiency of wind turbine maintenance is under the spotlight with the single biggest source of unplanned maintenance being the gearbox, which is susceptible to moisture contamination. Almost 80 per cent of gearbox failures are caused by bearing water, which is often accelerated due to poor oil quality management.
Chris Greenwood, CEO at Tan Delta Systems said: “Our SENSE-2 real-time monitoring utilises our world-leading sensor technology and associated analytics to detect any issues before the damage occurs, identifying subtle changes in equipment condition early. It can be fitted easily and efficiently to any existing equipment in any application and is configurable to any oil type.
“Detecting early signs of pitting on bearings within the wind turbines, allows the ability to pinpoint its optimal maintenance point, extending service intervals and therefore reducing the chance of catastrophic failure. The capability of the oil quality sensor gives wind turbine operators the opportunity to dramatically reduce lifetime operating cost. We work out the potential cost savings from the ability to forward plan maintenance and potential equipment failure but of course due to the increased reliability, the overall power output is increased.”
The real-time aspect of the system is what sets it apart, utilising unique active molecular-level analysis to detect all changes in oil condition and any contamination. The Tan Delta sensor works by providing a full-spectrum holistic (FSHTM) oil quality analysis, which continuously monitors the ratio of two key measurements, capacitance and conductance, to provide real-time insight.
The SENSE-2 Display Kit is easily installed on any wind turbine gearbox and will continuously monitor the real-time quality of the oil with the molecular analysis taking place every few seconds. Data can be displayed locally, integrated with an existing telematics system, or streamed directly to the Tan Delta online portal.
The OQSx-G2 oil quality sensor within the SENSE-2 kit is also available as a Mobile Oil Tester (MOT) Kit, created with workshops and mobile maintenance teams in mind. Any oil from any equipment can be sampled and tested simply and easily on-site in seconds. The sensor is used in conjunction with the MOT software, which operates on any Windows-based laptop, tablet or PC. Users simply install the MOT app, connect it to the sensor, collect the sample in one of the bottles provided and follow the steps in the software to test the sample.
For more information on Tan Delta’s SENSE-2 Display Kit and how it can benefit your business, please visit our product page.