MORE SAFETY – GREATER YIELDCONDITIONMONITORING

ALL-ROUND PACKAGECondition monitoring

Condition monitoring with Bachmann Monitoring means more than just measuring vibration. Mature hardware technologies, an innovative web-based analysis software and certified remote service technologies combine to form an all-round future-proof monitoring package.

9.000 CONDITION MONITORING SYSTEMS

equipped worldwide with Bachmann CM technology

EXPERTISE ADVANTAGE

� Worldwide monitoring of several thousand wind turbines including over 80 different types from a range of manufacturers

� Power range: 600 kW onshore to 8 MW offshore

� Fully certified CMS services: Hardware and software, remote monitoring, reporting, service and training

� Certified CMS – PLC-integrated or stand-alone, expandable easily and flexible, standardized and open communication interfaces, suitable for any turbine type

� Supply of condition monitoring solutions for wind energy, industrial engineering and maritime applications

SOFTWARE

WebLog Expert is the front end of the Bachmann condition monitoring system. It functions as the communication interface to the diagnostics system and enables secure, worldwide access to raw data, spectral data and trends from the monitored plant. Monitoring, visualization, diagnostics and analysis – with the powerful soft-ware you have all CMS data perfectly in view. The new reporting function enables the rapid creation of specific reports for different issues also beyond the turbine plant and limits of the server. It is also an important module for modern fleet mana- gement in service operations.

HARDWARE

No matter what kind of CM hardware you require – whether a complete CM system or individual sensor technologies, whether as a retrofit solution or as a completely integrated system, we have the right system solution for every requirement.

� Condition monitoring systems (stand-alone, TopBox or fully PLC-integrated)

� Sensor technologies

INSTALLATION

Specially developed in-house software tools are used for installation and commissioning as well as for documen-ting every step on site. This ensures a uniform installation standard and diagnostics quality at the same time. A standard color coding of the sensor cables simplifies installation and prevents connection errors.

CLOSE PARTNERSHIPComplete Solutions

We support our partners in the development of new wind turbines. Our automation solutions make it possible to considerably reduce plant down- time. With this we ensure that turbines can be kept permanently in available operation and that no loads occur that shorten the operational life of the machine.

TECHNOLOGY TRANSFER TO THE»We are open for the

CUSTOMER«Holger Fritsch, CEO of BAM

IN OPERATIONWORLDWIDERemote Service

Besides the innovative product hardware and soft- ware, Bachmann′s CMS offering includes a worldwide, GL-certified CM teleservice and remote monitoring service. This includes configuration, extensive analysis of all measured data, limit value monitoring, sub- sequent reporting as well as special training seminars. Through this service we offer you all our experience in condensed form. Clear, informative and optimally equipped for the future.

WHY CMS?Knowledge saves costs 08

ALL-AROUND PACKAGEA one-stop-shop for your condition monitoring needs

10

POWERFUL SOFTWAREEfficient analysis 12

REMOTE SERVICECMS specialists at your side 14

OUTPUTTransparent monitoring 15

A PROMISE OF QUALITYInstallation and support 16

MODULARSYSTEM CONFIGURATION

Flexible solutions

18

INSTALLATION & APPSA powerful overall concept 20

APPLICATIONS & USESVersatile efficiency 21

PRODUCT PORTFOLIOTechnical specifications 22

KNOWLEDGE SAVES COSTS Why CMS?

8

Targeted service & inspection Downtime for whatever reason means a loss of yield. The aims of condition based maintenance are:

Reduction of downtimes

Early detection of damage

Yield optimization

Savings in service expenditure

Fault finding is also faster with remote CMS analysis, for example video endoscopy can be targetted to effectively examine areas highlighted by vibration analysis.

Long-term cost saving The use of condition monitoring systems saves costs throughout the lifetime of a plant through detections which trigger timely interventions to correct:

major imbalance

misalignment

structural looseness

and thus prevent consequential damage.

Minor details, major impact A study by the Fraunhofer Institute for Wind Energy and Energy System Technology (IWES) compared the failure probability and the downtimes of the different plant components.

The result: Electrical and electronic components have a high failure probability, whilst the downtimes are rather less. Problems in the drive train on the other hand occur less often but cause the longest downtimes.

Our conclusion: Whilst fault detection is good, preventing them if possible is at least as important.

Condition monitoring systems supply the plant owners with a continuous stream of information about the state of the machine and plant components. This makes it possible, during operation, to detect in advance any impending damage to the installation. The benefit: Repairs and maintenance can be planned systematically, plants can be kept longer on the grid, and consequential damage prevented. Thedifference between planned repair and sudden failure is enormous – this savestime and money.

Example of repair costs*

$ 250,000

$ 200,000

$ 150,000

$ 100,000

$ 50,000

$ 0with CMS (early planned repair)

without CMS (total loss of the main component)

damaged generator bearing damaged gearbox bearing

* based on experiences costs of a total loss are 10 or more times higher than a detected damage in an early stadium and its repair

$ 6,000$ 25,000

$ 60,000

$ 250,000

9

condition.monitoring

ALL-AROUND PACKAGE

A one-stop-shop for your condition monitoring needs

Remote Monitoring Center USA

Remote Monitoring Center Europa

Remote Monitoring

Center China

10

Bachmann monitoring Currently monitors several thousand wind turbines of from

25 different manufacturers in the wind power sector

Supplies condition monitoring solutions for wind energy, industrial engineering and maritime applications

Provides full range of condition monitoring services (hardware, software, remote monitoring, service and training) from a single source

Provides international project expertise – from commissioning to after-sales service

Also offers condition monitoring solutions, systems and services for offshore applications

Has worldwide sales and service structures

Is the only supplier worldwide that can offer certified PLC-integrated condition monitoring systems with a complete service structure

Worldwide service round the clockWith its sites in Germany, China and the USA, Bachmann Monitoring offers a worldwide monitoring service that can be used round the clock and anywhere in the world. Our certified remote monitoring centers evaluate the measured data from all monitored plants through extensive analyses and comparison with it with refe-rence data. The plant manager then receives not only verified fault messages, but also an assessment of the current operational relevance as well as specific action recommendations. The remote monitoring service is transparent since the customer can always view plant status via the Internet.

Whether it is hardware or software, analysis or consulting – every Bachmann monitoring solution is based on more than 20 years of monitoring experience with several thousand wind turbines currently monitored world wide with GL-certified monitoring systems. Valuable know-how that we are glad to also make available to you.

11

condition.monitoring

EFFICIENT ANALYSISPowerful software

Traffic light systemIf predefined limit values are exceeded, »WebLog Expert« initiates an alarm message which is indicated to the user in a status window, and which can be sent by email. Extensive tools for signal analysis, such as envelope spectra, amplitude spectra, or frequency-based characteristic values support the diagnostics specialist in detecting and interpreting changes in the characteristic »healthy picture« of the monitored components.

Integrated trend analysisAn integrated database enables the trend analysis of the data recorded from individual machine components and units over an extended time period.

Acoustic monitoringAs well as convenient and clear visualization, »WebLog Expert« also provides the possibility to make sensor signals audible. In this way, irregularities in the measured spectrum can be assessed acoustically – without, for example, having to travel to the offshore wind farm itself – which very often allows an actual fault to be identified quickly.

»WebLog Expert« is the client-based software of the Bachmann condition monitoring systems. It functions as the communication interface to the diagnostics system and enables secure and location-independent access to the condition data from the wind turbine.

12

WebLog Expert workstation

WebLog Expert workstation

WebLog Expert workstation

The Bachmann Online CMS Ω-Guard® provides worldwide access to the status data of the monitored plant from any online workstation.

Operational control of remote plants

Ω-Guard® system Commissioning and configuration

Condition monitoring system WebLog Expert server

Sensors

Internet

13

condition.monitoring

CMS SPECIALISTSAT YOUR SIDE

Remote service

A team of CMS specialists in the CM service centers in Germany, China and the USA currently look after several thousand wind turbines round the clock. From over 20 years of experience and continuous »knowledge updating«, this team can offer a high level of diagnostic accuracy. Their tasks include: confi-guration work, comprehensive analysis of all measured data

(time range, frequency range, amplitude spectra, envelope spectra); limit value monitoring and subsequent reporting. The decision templates and action recommendations derived from the analysis of the measured data and the optimized yield resulting from more efficiently controlled operation save our customers enormous costs in service and repair work.

Besides the innovative product hardware and software, Bachmann′s CMS offering includes a worldwide, GL-certified CM teleservice.

14

TRANSPARENTMONITORING

Output

Transparent monitoring of wind power plants is ensured through the extensive tracking of monitoring activities. A ticket system, reports and training concepts round off the service offering of the Bachmann condition monitoring systems.

CMS reportDifferent report types such as event and incident reports, fleet reports or diagnostic reports are created by our experts based on their many years of experience.

Ticket systemThe ticket system of the »WebLog Expert« client-based software is used as the central monitoring tool for wind power plants.

Training conceptWe offer suitable training concepts for the independent monitoring of wind turbine fleets. The training covers the basics of condition monitoring as well as providing a detailed knowledge of the hard- ware and software of the condition monitoring systems.

Training catalogue Bachmann electronic2018

1/1

Max Mustermann Remote Monitoring

Bachmann Monitoring GmbH Weimarische Str. 10 07407 Rudolstadt Tel.: +49 (0) 3672 3186 - 100 Mail: m.mustermann@bachmann.info>

EventReport

Turbine Number: XYZ-1-CMS-XXX92000Y Fault Location: Gearbox Characteristic Value: HSS-GS_ABC HR30234J _BPFI (7.120.1742.2) Report Date: 2014/06/02

Findings

Increasing trend of the inner race roll over frequency of the high speed shaft bearing ABC HR30234J with harmonics and sideband frequencies at an interval of the high speed shaft run frequency.

Recommendation

– check the condition (temperature/noise behavior) of the high speed shaft bearing – check the oil for increased particle concentration – assessment/endoscopy of the high speed shaft bearing, especially the inner race

Priority

Rise of progression: We recommend that the turbine is operated only after an inspection has been carried out by qualified personnel. Feedback regarding the result of the inspection should be sent to the monitoring centre.

RM EventReport_Muster_schrift.pdf 1 12.06.2014 10:32:37

15

condition.monitoring

General CMS Installation Instruction Revision/05

General CMS Installation Instruction

#CMS General CMS Installation InstructionDCC #Document Number Revision/05

Turbine Specific Installation Instruction (Bachmann Monitoring GmbH)

Recommended sensorlayout for General Electric 1.5 Based on setting code: 1B1P2H1G REV 002 page 5 / 6

Cable Routing top view

Cable Routing left view

Cable Routing right view

Turbine Specific Installation Instruction (Bachmann Monitoring GmbH)

Recommended sensorlayout for General Electric 1.5 Based on setting code: 1B1P2H1G REV 002 page 1 / 6

!!!! This document is an attachment to the “BAMENG_20130423_General_CMS_Installation_Instruction_rev02” (GCII) or newer. Read both documents carefully before commencing the installation.

MNBRG1AX AI11111 / orange BAM 500 Main Bearing Housing axial direction

MNBRG1MYB AI22222 /light blue bridge Main Bearing Housing radial 270° 300°

None Not used None

PST1 AI44444 / yellow BAM500 Bearing or Gearbox Housing PST [Ring1] radial 210° 270°

None Not used None

HST1AX AI66666 / purple BAM 100 Gearbox Housing axial close to IMS & LSS

HST2 AI77777 / gray BAM 100 Bearing or Gearbox Housing 0° 90°

GEN1DE AI88888 / dark blue BAM 100 Bearing or Generator

Housing radial 150° 270°

GEN1NDE AI99999 / green BAM 100 Bearing or Generator

Housing radial 150° 270°

GEN1SPD Tachometer___C1C1C1C1 / brown

BES M18MLPSC12ES04G

W

HSS GEN1DE bearing shield

AI / C1 channel AIC212 BAM 500 acceleration sensor, sensitivity 500mV/g MnBrg (1; 2) Main bearing BAM 100 acceleration sensor, sensitivity 100mV/g PST (1; 2; ...) Planetary Stage µbridge (MYB) force sensor for lower frequencies HST (1; 2; ...) Helical Stage GEN1DE Generator bearing DE (3Dmodel) mounting position GEN1NDE Generator bearing NDE GEN1SPD AX axial mounting direction

General CMS Installation Instruction GCIIRevision/05

3 Safety

3.1 General safety instructionsThe following basic safety instructions are intended to prevent personal injury and material damage. The operator must ensure that the basic safety instructions are observed.Personnel assigned for operation and maintenance of the modules must be adequately qualified or authorized.The manual must be fully available to operating personnel at all times.

Mounting and commissioning only by qualified personnel.

If something is unclear or if additional information is required, please contact your technical service representative at Bachmann Monitoring GmbH.

Assembly

WARNINGBodily injury due to improper installation!• Use suitable tools.• Use personal protective equipment.• Comply with locally applicable guidelines and safety regulations.

WARNINGElectric shock due to exposed cable!• Do not damage cable insulation• Do not use any sharp/pointed objects.

WARNINGElectric shock due to live parts!• Do not touch any electrical or live parts• Isolate live parts from the power supply and secure against acci-

dental restart

3.2 TrainingWork on wind turbines must only be carried out in compliance with the currently applicable health and safety regulations.Specialist personnel must be trained regularly.The special regulations for wind turbines (e.g. BGI 657 – wind turbines) must be observed.

05 / 04.09.2014 GCII-6

INSTALLATION AND SUPPORT

A promise of quality

General CMS Installation Instructions

� Health and Safety Equipment required

� Overall installation rules and tools

Turbine Specific Installation Instructions

� Drivetrain specific sensor installation

� Wiring recommendations

1 2

16

Example of End of Installation Protocol 14.11.2013 00/01

CMS End of Installation Protocol(Bachmann Monitoring GmbH)

Start of Installation:

2013-03-26 13:22:51 End of Installation:

2013-03-27 14:20:51

Submission timestamp:

2013-03-27 14:22:07 Submission ID:

1341274

Site Name: Millstream Installing Technician

John Doe

Customer: Mill Engines Corp. Reporting Technician

John Doe

WTG Manufacturer

Millstone Site Representative

Jane Doe

WTG Type Miller 1.5 System ID Millstream-MI155498WTG S/N MI155498 CMS S/N 435645.005Turbine No. 2Wiring test successful

yes Installation Completed

yes

Remaining WorkGPS Coordinates WTG ID Photo

lat= 50.729121 , long=11.335866, alt=199.07101862554833, accuracy=32.0

01/14.11.2013 EIP- 1

The foundation of an effective condition monitoring system largely depends on proper installation. Installation for every Bachmann condition monitoring system is readily adapted to each turbine make/model, with use of extensive documentation and mobile apps, ensuring stringent quality metrics are met along each step of the way. Automated installation tools streamline each installation, document the in-situ work of each project, and provide customers with reports for their databases.

End of Installation protocol

� Mobile application for technicians

� Tracks and documents installation

Function Test Protocol

� Automated update and hardware commissioning tool

3 4

17

condition.monitoring

FLEXIBLE SOLUTIONSModular system configuration

Condition monitoring systems are increasingly being used as a preventative measure. They enable any impending damage to wind turbines to be detected early on and rectified. Bachmann has met the increa-sing demand for this so far with a PLC-integrated sys-tem solution that enabled the logging, analysis and evaluation of the plant condition in parallel with the PLC program. The Retrofit CMS systems are alterna-tive condition monitoring systems that are particularly suitable for the retrofitting of wind turbines: The CMS module here runs independently of the controller en- vironment, either as a complete stand-alone solution or as a TopBox variant in an existing control cabinet.

Complete offering – and much experience Besides the special hardware and software, Bachmann′s system offering includes a worldwide Monitoring Service, provided by Bachmann Monitoring GmbH, Bachmann′s German subsidiary: Our diagnostics spe-cialists based in Germany, China and the USA evaluate the measured data collected by the CMS module through extensive analyses and compare it with reference data. This enables them not only to notify plant operators of verified fault messages, but also provide appraisals of the current operating state of their plants and their wind farm. The experts at Bachmann Monitoring can draw on over 20 years of experience for their analysis processes: They currently monitor several thousand wind turbines from over 25 different manufacturers.

After »Ω-Guard«, the world′s first PLC-integrated condition monitoring system to be certified by Germanischer LLoyd, Bachmann offers other systems for retrofitting wind turbines.

Stand-alone CMS system: Control cabinet dimensions can be adapted individually, in this case a 380 x 380 x 210 mm variant, fastening with fixing feet, direct mounting or magnets.

18

Stand-alone solutionBesides the power supply for the CPU and the measuring module, an autonomous control cabinet houses the two modules themselves, and provides the option to retrofit a commu-nication unit (e. g. router) as well as all relevant components for the sensors.

TopBox solutionPLC-independent mounting in the existing control cabinet, few hardware and installation requirements.

PLC-integrated solutionIntegration in the existing Bachmann controller environment as well as in the existing control panel, few hardware and installation require-ments.

»Ω-Guard®« condition monitoring system � Online monitoring

� All-in-one package (sensors, wiring, measuring, evaluation, reporting)

� Stand-alone CMS, TopBox CMS or PLC-integrated CMS

� Over 9,000 wind turbines equipped with Bachmann CMS

Detail: The installation location and type of sensor to be installed are speci-fied beforehand for each turbine type. The individual mounting sets ensure very efficient and time saving installation.

19

condition.monitoring

A POWERFULOVERALL CONCEPT

Installation & Apps

Online condition monitoringThe data from all the monitored plants is consolidated in the Bachmann Monito-ring Center and analyzed by experienced diagnostics specialists. Bringing together the characteristic data from the condi-tion monitoring and the operating para-meters of the automation system enab-les changes to measured values to be explained in advance and faults preven-ted. Depending on the service agreed, the plant manager not only receives a verified fault message, but also an assessment of the operational relevance

and concrete action recommendations.

Mobile measurements (offline)Mobile measurements in the field are also possible, for example, as part of the installation acceptance or routinely at the end of the warranty period. The great benefit of mobile measurement with Bachmann is the fact that the same basic technology is used as for online diagnostics. For this we will install the required sensors on your wind turbine for an agreed period in order to monitor selected characteristic values. Analysts

with experience in the monitoring of several thousand wind turbines prepare the measured data and supply you with a meaningful status report on the con-dition of the monitored components.

Advisory supportWorldwide access to plant data is pos-sible thanks to the web-based commu-nication to the Bachmann condition mo- nitoring system. In this way Bachmann can provide advisory support at any time to operators with their own monitoring center.

The result of online condition monitoring largely depends on the proper installation, configuration and commissioning of the CMS system, as well as on the fast and correct response to reported status changes. Wind turbines are complex systems that are continuously exposed to changing operating conditions. The modular Bachmann condition monitoring system is therefore adapted individually to the particular characteristics of the turbine type and configured accordingly.

All the system components used for condition monitoring including the online remote Monitoring Center are certified in accordance with the regulations of Germanischer Lloyd. The Bachmann automation compo-

nents are furthermore provided with several internationally recognized approvals for use in all Bachmann automation sectors.

Internationally recognized approvals

20

VERSATILE EFFICIENCY

Applications & Uses

Our sectorsBachmann condition monitoring solutions are used in all sectors where Bachmann controllers are also leading the way:

Wind power (onshore and offshore)

Maritime applications

Industry & machine building

Our focusNo matter how varied the application fields of our CMS solutions are, the focus always stays the same: We concentrate our atten-

tion on different plant components of wind turbines such as rotor bearings, gears and generator bearings, which provide infor-mation about the condition of the plant. Alongside casing vibration we also record physical measured values such as:

Wind direction and speed

Plant output

Temperatures

Pressure

Lubricant consistency

Particles in the oil

All-round secure communicationAt Bachmann, secure data transmission and the confidentiality of the recorded data have top priority. In order to ensure absolutely secure CMS communication, Bachmann offers different possibilities to protect outgoing and incoming con- nections all round: For example, through different firewall options as well as VPN accesses to the plant network. After all, »secure« at Bachmann means »secure all round«.

Condition monitoring systems have long been established in the wind power sector as an effective measure for yield optimization. They are now also ensuring greater transparency and fewer downtimes in other sectors.

21

condition.monitoring

TECHNICALSPECIFICATIONS

Product portfolio

Ω-Guard® system variantsThe GL tested and certified CMS Ω-Guard® condition monitoring system provides you with an intelligent monitoring system without any mechanical moving parts (hard drives, fans) for use in harsh environmental conditions.

Technical Data: Ω-Guard®

Analog measuring channels

Number of channels 12 analog inputs (9 inputs with IEPE interface for piezovibration sensors and 3 inputs, ±10 V)

Sampling rate up to 50 kHz, all channels including position detection(encoder signal), synchronized sampling

Measuring range IEPE standard, voltage (±10 V)

Sensor power supply

IEPE 4 mA

Incremental/counter inputs For external sensors: 24 V / 5 Vshort-circuit-proof

Power supply

Wide range power supply unit 100 .. 240 V / 50 .. 60 Hz / 50 W

Interference immunity

ESD EN 61000-4-2

Electromagnetic field EN 61000-4-3

Burst EN 61000-4-4

Surge voltage EN 61000-4-5

Line-conducted RFI EN 61000-4-6

DIPS(voltage dips)

EN 61000-4-11Operation with wide-range power supply unit

CPU

Interfaces Ethernet, FASTBUS

Communication LAN, GRPS, modem

22

BAM100 / BAM500 acceleration sensorsThe tried and tested acceleration sensors are provided with an extremely robust housing, a hermetic sealing and an insulated housing, and thus offer proven ser-vice even in demanding ambient conditions. Their minimally invasive mounting on the object as well compact dimensions make them suitable for difficult to access measuring points.

μ-Bridge sensorThe »μ-bridge« sensor developed in-house is used for measuring sound waves and bending vibrations in machines and plants (e.g. components, fixed parts). The body sound waves emitted from machine components indicate the state of wear of a turbine component.

Technical Data: μ-Bridge SensorOperating mode IEPE standard

Operating current 4 .. 10 mA

Output voltage (Offset) 11 ±0,5 V

Max. level control 8 V

Sensitivity 0,7 V/N

Signal-to-noise ratio -83 dB

Carrier-to-interference ratio -79 dB

Lower limit frequency High pass 1st order, ƒg = 1.6 Hz

Upper limit frequency ƒg > 10 kHz

Technical Data: BAM100 / BAM500 SensorSensitivity 100 mV/g | 500  mV/g

Output ICP®-compatible

Measuring range 0,5/0,2 Hz-14 kHz

Sensor connection M12

23

condition.monitoring

TRUST THROUGHEXPERTISEApplications for the wind sector

Many of the leading global manufacturers and operators of wind energy plants rely on us. Together with them, we are setting new benchmarks and achieving new success.

»I′M CAPTURING NEW MARKETSAND INCLUDING… MY CMS«

ABO Wind

26

CMS PARTNERSHIP FOR THEDIGITAL BUSINESS MODEL

BKW Energie AG

28

PROFITABLECONDITION MONITORING

CSR Wind Power

30

COMPLETE TRUSTWestWind 32

26

ABO Wind demonstrates very well how the wind power sector has matured. The customer rela-tionship developed from the very start, when both companies worked together on making further improvements to the first CMS at ABO in service operations. »Today, this is an establis-hed company, making successful steps towards internationalization. Any entry into global mar-kets naturally requires good planning. I have the greatest respect for what they have achieved,« says Holger Fritsch, CEO of Bachmann Monito-ring. The journey towards this includes CMS and

Bachmann expertise already integrated in the package. »This is a clear demonstration of trust by ABO Wind. We will make sure that it pays off for them,« says Fritsch. Future issues are discussed and CMS projects are developed in joint workshops. Particularly in countries where operators still have little experience with local logistical challenges, good early detection can save a lot of money and even more annoyance. A standard CMS also makes it easier for the com-pany to set up its own service business in the target markets.

ABO Wind was one of Bachmann′s first customers to consistently pursue the implementation of condition monitoring systems. Both companies are today working together on the internationalization of ABO Wind and are developing strategies for a CMS that is standard worldwide from Argentina to Iran.

» If you are new to a country, it helps toknow the CMS already. A reliable earlyfault detection system saves money andeven more annoyance with overseaslogistics. «

Matthias Bockholt

Chairman at ABO Wind

ABO Wind is an international project developer and wind farm manager from Wiesbaden. Wind power has been the company′s core business since 1996, and it already has 600 wind turbines connected to the grid. ABO Wind provides the long term operational management of wind farms, and offers service and maintenance as well as expert technical reports.

www.abo-wind.com

»I′M CAPTURINGNEW MARKETS ANDINCLUDING… MY CMS«

How the long-standing customer relationship helps

ABO Wind with internationalization

27

condition.monitoring

As part of its predictive maintenance strategy, BKW Group in Germany tested the condition monitoring system of Bachmann Monitoring. The test was so successful that the wind farm operator decided to form a strategic partnership with Bachmann Monitoring! The future aim of the two companies is to roll out a comprehensive health monitoring system for the wind turbine fleet. Status information for imbalance, rotor blade, gears and tower is kept secure in the ownership of BKW and revolutionizes its service business at its plants.

Headquartered in Bern, the Swiss capital, the BKW Group const-ructs and operates energy pro-duction and supply infrastruc-tures and offers digital business models for renewable energy. BKW currently operates ten wind farms in Germany. It invests hea-vily in wind power and is positi-oned as a medium-sized power station operator in Europe.

www.bkw.de

Sustainable management and above-aver-age wind yield are BKW′s highest priorities. The company achieves this by implementing efficient operational control and a predictive maintenance strategy. During the construc-tion and operation of the wind turbines, the company only carries out those tasks itself by which it can provide added value on account of its own expertise. In the other areas, BKW collaborates with partners with whom it seeks to establish long-term contractual relations. Bachmann Monitoring is its partner for con-dition monitoring. Together with BKW it is developing a comprehensive, state-of-the-art health monitoring system, which predicts any maintenance needs and can thus optimize the costs for maintenance and logistics. »In order to standardize our service business, we also need digital standards for the condition moni-toring technology, in other words: We defini-tely want a CMS with some »sense and intel-ligence«,« says Martina Dabo, head of asset management and development. Holger Fritsch, CEO at Bachmann Monitoring adds: »The part-nership is driving progress since it offers us several formal freedoms. We can concentrate

completely on evaluating which plants would benefit from balance monitoring, a rotor blade CMS, gear or tower monitoring. We then draw up the separate individual projects on the basis of the evaluation and implement them.« BKW is pioneering the digitization of the energy sys-tem and is using its own data to provide added value to the customer with additional service options. The data is kept securely on the custo-mer′s servers so that they have the rights to their own information at all times.

BKW spent a long time thoroughly conside-ring whether to invest in a CMS system. »For them, it was important to examine Bachmann′s knowhow and solutions before forming a stra-tegic partnership. The human factor was also naturally a key factor here. Both companies have a high level of quality awareness. That′s why the partnership works so well,« says Holger Fritsch. The system was initially installed at the Bockel-witz wind farm in Saxony. A task for which Bach-mann won the respect of the customer. This resulted in a considerable number of orders for other parks such as those for the Dubener Platte, Bippen, Holleben and Sendenhorst.

CMS PARTNERSHIPFOR THE DIGITALBUSINESS MODEL

Revolutionizing the service business with plant data

28

29

condition.monitoring

PROFITABLECONDITION MONITORING

Wind turbines in a challenging environment

30

A fully functional condition monitoring system considerably increases the profitability of wind turbines. CSR Wind Power recognized this fact very early on and now has its own CMS department which equips its wind turbines with suitable systems. The Bachmann M1 automation system has been used for several years as the controller for the CSR Wind Power′s 2 MW turbine. Bachmann′s tried and tested condition monitoring solution is now also being used in their plants.

CSR Wind Power has ten years‘ experience in the development and construction of wind turbines. More than 100 wind turbines are currently being delivered to the Huarun Power Group in Hubei province (China) and commis-sioned. Initially 28 of these systems are being fitted with the Bachmann CMS.

Challenging environmental conditionsCSR Wind Power has been involved in the con-dition monitoring of wind turbines for many years, and now has its own specially created department for this area. In recent years they have used systems from a wide range of diffe-rent manufacturers. »We have thus acquired a comprehensive knowledge of CMS,« Xiangyan Ruan, head of CMS at CSR Wind Power, explains. The diverse geography of China is a particular challenge. »The intertidal zone with saline-alkali soil in Liaoning province, Inner Mongolia with its very low temperatures and the high alti-tudes of the provinces of Gansu, Yunnan and Guizhou – our wind turbines and CMS systems must be able to withstand all these environ-mental conditions,« Xiangyan Ruan explains the difficulties involved.

Profitable cooperationThe controller system for the 2 MW turbines has been implemented with Bachmann for several years. »We know and appreciate the benefits of the Bachmann automation solu-tion – the high level of reliability speaks for its-elf,« Xiangyan Ruan says. »On the basis of this

experience we are sure that Bachmann′s CMS will function just as well.« The idea behind the project is simple. »We know our wind turbines and the environmental conditions in China like no other – and Bachmann has extensive expe-rience in the field of condition monitoring,« Xiangyan Ruan explains. »Together we now have the opportunity to develop an advanced, practical and comprehensive CMS solution for wind turbines in China.«

Step by step to greater successThe next steps for CSR Wind Power are already planned. The Bachmann CMS will thus be tem-porarily installed as a stand-alone solution. »We want to be able to understand the system and also examine it,« Xiangyan Ruan explains the idea behind it. A continuous and close exch-ange with Bachmann is also planned for this. The subsequent step will focus on the testing of the integrated CMS. »Bachmann correlates measured values with other operating para-meters, considerably increasing the diagnostic reliability of the condition monitoring, « exp-lains Xiangyan Ruan. »The possibilities resulting from this are very exciting.« Precise statements on the condition of different plant sections can thus be made, the lifespan of already dama-ged parts extended, and maintenance dates scheduled precisely. CSR Wind Power is excited about the results of the test in all cases: »This approach will soon provide us with a reliable CMS perfectly tailored to the requirements of our wind turbines and the Chinese market,« summarises Xiangyan Ruan.

CSR Zhuzhou Institute CO., Ltd. or CSR Wind Power for short, was founded in August 2006 as a subsidiary of CSR Corporation Ltd. The company develops, builds and sells wind turbines and is one of the top ten in the Chinese wind power market. CSR Wind Power has over 50 years of experience in the construction of locomoti-ves and other components for the Chinese railway. The company is renowned for its wind turbines, which demonstrate a proven track record in terms of reliability, even under varying environmen-tal conditions.

www.wind.csrzic.com

31

condition.monitoring

WestWind is one Germany′s leading full-service providers for the development of projects in the wind energy sector. The company′s portfolio ranges from the design of wind farms to the operational management of its own plants or those of third parties. Bachmann Monitoring spoke to Jens Rösler, head of technical operational management at WestWind, about the benefits of condition monitoring, Bachmann′s involvement and about friendships.

TOTAL TRUSTWestWind relies on condition monitoring from Bachmann –

as a matter of conviction

Founded in 1998, WestWind energy is one of Germany′s leading full-service providers for wind energy projects. The service ranges from the detailed plan-ning of wind farms, to financing and building supervision, right through to the technical and com-mercial operational management of wind farms. Based in Kirchdorf in North Germany, the company has around 25 employees.

www.westwindenergy.net

Bachmann Monitoring: Why do you use a condition monitoring sstem?

Jens Rösler: CMS allows us to ensure the early detection of damage in order to prevent the avoidable occurrence of major hardware failu-res and to optimize the planning of repairs. We try, for example, to move any repairs if possible to low wind periods, which occur between May and August. The early detection of wear damage, particularly to the bearings of major components of the drive train, and the resulting plannable replacement of components without any major downtimes, ensure the high energy availability of the wind turbines even when damage occurs. Reduced insurance premiums are another attractive benefit of the use of CMS.

Bachmann Monitoring: Why did you choose the CMS solution from Bachmann?

Jens Rösler: The innovative and future-proof concept greatly impressed us. From our first interactions, we noticed that the Bachmann employees are absolutely professional in their work, and do not settle for their success to date, but always keep improving in order to keep up with the current state of the art. The price and the full-service monitoring offered also impressed us. The entire concept matches the philosophy at WestWind wonderfully. Since 2009, all plants with

gears are equipped with the Bachmann CMS and we are completely satisfied with it.

Bachmann Monitoring: Where do you use the Bachmann system?

Jens Rösler: All wind turbines with gears used in operational management at WestWind are always monitored by Bachmann Monitoring. This includes an NM 60/1000 (NEG Micon), two AN 1300s (AN Bonus) and seven GE 1.5 sl turbines. These belong to the Marklohe/Wohlenhausen, Wagenfeld, Frestorf, Frestorf-West and Haustedt wind farms (all in Germany).

Bachmann Monitoring: What have been the specific benefits of the Bachmann system so far?

Jens Rösler: In the past we had a lot of main bearing damage on the GE turbines, which consisted of faulty generator bearings and two occurrences of damage to gears. One of these occurrences could be repaired on the instal-lation thanks to early detection. Currently, we have a damaged generator bearing on a GE 1.5 sl. In the planned repair, it was possible to also replace a partly damaged slip ring. During the repair, it was also discovered that a bea-ring shield was damaged. The costs for these issues are around 15,000 euros. In the worst

32

» We are completely satisfied with theBachmann CMS. «

Jens Rösler, Head of technical operational management

at WestWind energy

case, if it hadn‘t been for the continuous online monitoring provided by Bachmann Monitoring in Rudolstadt (Germany), the generator could have been totally damaged. Furthermore, this could have occurred in autumn and win-ter when the best wind conditions are pre-sent. The resulting damage, including the loss of yield, would then easily be ten times more expensive than the repair carried out.

Bachmann Monitoring: What is the daily use of the system like?

Jens Rösler: As we have a contract for full-ser-vice monitoring with all installations and have had very good experience with it, we just have to

log into WebLog for control purposes. We receive a great deal of support from Bachmann and have a high trust in the experienced Bachmann technicians that daily monitor the measured values. We are always notified of any abnorma-lities. We also find the regular customer training courses very valuable. The collaboration is simply excellent. It is open and based on trust, in fact one can honestly say that some real friendships have developed from it. We urgently recommend all our existing and future customers of wind turbines with gears to have their installations monitored with the Bachmann system. We are looking forward to more innovative ideas from Bachmann that will help to further increase the availability of our wind turbines.

33

condition.monitoring

BACHMANN TRAININGSOFFERINGSBenefit from our expertise

Solid know-how combined with first-class products is the key to perfect automation. We offer you both. Take advantage of our extensive training program, which we will gladly adapt to your individual needs.

SOLUTION CENTER The SolutionCenter as an integrated and user-friendly engineering tool for project engineering, commissioning, configuration and diagnostics. The training also includes an introduction to programming and visualization.

MODEL BASED DESIGN The MATLAB® program package from MathWorks offers a software tool for model-based development of controller applications. »M-Target for Simulink«® enables the user to integrate seamlessly in this development process inside the M1 controller environment.

POWER MANAGEMENT The safety and efficiency of the electrical energy supply are placing increasing demands on generation, transmission and consumers. This training seminar provides the knowledge required to use Bachmann grid measurement, monitoring and synchronization modules in the M1 controller system.

SAFETY CONTROL This seminar offers a practical and basic understanding of how to implement functional safety. You are shown how to program safety applications based on the Bachmann safety products in hardware and software.

CONDITION MONITORING SYSTEM Condition monitoring involves the monitoring of the machine state through the measuring and analysis of meaningful physical variables. The training covers the basics of condition monitoring as well as providing a detailed knowledge of the hardware and software.

Benefits of engineering training

� Perfect program adaption to individual requirements thanks to the modular concept

� Intensive knowledge transfer through hands-on training

� Training seminars held on site at Bachmann or as webinar

� Access to the in-depth knowledge of Bachmann application engineers

ALWAYS KEEPINGUP-TO-DATE

Engineering training seminars

Precisely tailored training seminarsBachmann′s training offering ranges from the proven standard training seminars right through to workshops tailored to your individual require-ments. The modular training concept enables the creation of training programs tailored precisely to company requirements. The training is always centered around intensive knowledge transfer and hands-on practice with special problem sol-ving tasks. The training sessions are held either in a Bachmann branch office or directly on site at the customer′s premises. Individual modules can also be offered as webinars if required. Following each training course, the participants will receive a personalized certificate.

No questions unansweredIf a question remains unanswered despite the extensive training offer, Bachmann customers benefit from the know-how of several application engineers. These work in close proximity to the development team. They know every small detail of the Bachmann solutions and can therefore make use of all options available.

Even though the training needed for engineering is kept to a mini-mum thanks to the standard development environment, updating and deepening one′s knowledge of individual engineering areas at regular intervals is worthwhile. The combination of the user′s sound knowledge with first-class products is ultimately the key to perfect automation.

36

Basic Training User Training Advanced Training

Wind.Applications

Wind Turbine Template(WTT)

Wind Power SCADA(WPS)

M1 ServiceCenter

IEC 61400-25

Condition Monitoring

atvise® SCADA

Industry-specifictrainings

Park controller

Basic knowledge of automation required

Basic training and specific knowledge

recommended

Basic training and specific knowledge of programming required

PLC programmingBachmann automation

Redundancy

(Ethernet real-time protocol)

Advanced Visualization

bluecom

VisualizationM1 webMI pro

Grid measurement and monitoring

Safety technology (Safety Developer)

Service technician

C/C++ Developer

Application development with M-Target for Simulink®

with MATLAB® / Simulink®Model-based development

Customer-specific workshops

37

condition.monitoring

www.bachmann.info Bro

chur

e Co

ndit

ion

Mon

itor

ing

EN |

Sub

ject

to m

odif

icat

ions

© 1

1/20

17 b

y B

achm

ann

elec

tron

ic