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David Clark: 2013 Sandia National Laboratoies Wind Plant Reliability Workshop

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Sandia National Laboratories: Energy & Climate: Renewables
Sandia National Laboratories: Energy & Climate: Renewables

The document discusses myths around condition monitoring of wind turbine drive trains. It presents data on common failures in gearboxes from different inspection techniques and discusses sensor locations that can detect these failures. Charts show examples of vibration data from the high speed section, planetary section, and generator bearing that indicate developing faults. The document argues that condition monitoring can detect planet section issues, is cost justified, and helps avoid unexpected breakdowns through trend analysis of key components.

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Bachmann electronic GmbH CONDITION MONITORING OF THE DRIVE TRAIN MYTHS end of warranty and permanent installations - David Clark
Bachmann electronic GmbH WHAT WILL FAIL? AVERAGE SIZE 1.5-2.5MW
Bachmann electronic GmbH WHAT WILL FAIL AT EACH SENSOR LOCATION?
Bachmann electronic GmbH  TURBINE GEARBOX COMMON INSPECTION TECHNIQUES Component detection percentages on a typical gearbox  VISUAL INSPECTION BORESCOPE INSPECTION VIBRATION ANALYSIS   High Speed Pinion 50% 50% 100%  Intermediate Wheel & Pinion 100% n/a† 100%  Low-Speed Wheel 100% n/a† 100%  Sun Gear No 30%§ 100%  Planetary Gears (3) 10% 30%§ 100%  Ring Gear 20% 30% 100%  High Speed Bearings (3) No 100% 100%  Intermediate Bearings (2-3) No 50%‡ 100%  Low Speed Bearings (2) No 50%‡ 100%  Planetary Carrier Bearings (2) No 30%§ 100%  Planetary Gear Bearings  (6 drCRB) No 30%§ 100%  † Clearly visible during visual inspection by removal of inspection cover  ‡ Depends upon gearbox make/model, oil level and bearing configuration  § Requires several rotations of rotor and to inspect 100%, adding several hours to inspection  By Don Roberts and David Clark
Bachmann electronic GmbH DIFFERENT TYPES OF VIBRATION UNITS- Velocity, acceleration, displacement, demodulated/enveloped, time waveform, overall. TIME WAVEFORM VIBRATION SPECTRUM FFT
Bachmann electronic GmbH CONDITION MONITORING MYTHS . Need lots of data, lots of measurements, with a baseline . Too difficult to understand the data . Not cost justified . Cannot detect planet section issues …..All condition monitoring is the same
Bachmann electronic GmbH FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz 30/04/2004 2:14:30 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/All 0.991 g rms 30/04/2004 2:14:30 p.m. O/All 0.991 g rms <set RPM> FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz 7/07/2004 5:04:47 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/All 0.468 g rms 7/07/2004 5:04:47 p.m. O/All 0.468 g rms <set RPM> RING GEAR
Bachmann electronic GmbH FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz 7/07/2004 5:04:47 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/All 0.468 g rms 7/07/2004 5:04:47 p.m. O/All 0.468 g rms <set RPM> FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz 30/04/2004 2:14:30 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/All 0.991 g rms 30/04/2004 2:14:30 p.m. O/All 0.991 g rms <set RPM>
Bachmann electronic GmbH HIGH SPEED SECTION (HSS)
Bachmann electronic GmbH HIGH SPEED SECTION (HSS) secs 0 1 2 3 4 5 6 7 8 g -0.8 -0.6 -0.4-0.4 -0.2 0 0.2 0.4 0.6 O/All 0.062 g RMS Machine Note (3/8/2010 11:09:42 AM) Changed to High RPM recording 3-8-10 RK T03 Gbx HighSpeed Horizontal [Tach] Acc Wfm 8000 ms 6/23/2011 8:03:10 AM O/All 0.062 g RMS 1802.787 RPM T04 Gbx HighSpeed Horizontal [Tach] Acc Wfm 8000 ms 3/14/2011 3:18:04 PM O/All 0.23 g RMS 1829.291 RPM
Bachmann electronic GmbH PLANETARY SECTION secs 0 10 20 30 40 50 60 g -1 0 1 2 3 4 O/All 0.312 g RMS Machine Note (3/8/2010 11:09:31 AM) Changed to High RPM recording 3-8-10 RK T04 Gbx Planetary Horizontal [Tach] Acc Wfm 64000 ms 3/14/2011 3:10:40 PM O/All 0.312 g RMS 20.484 RPM T03 Gbx Planetary Horizontal [Tach] Acc Wfm 64000 ms 6/23/2011 8:10:43 AM O/All 0.035 g RMS 20.297 RPM
Bachmann electronic GmbH CONDITION MONITORING MYTHS . Need lots of data, lots of measurements, with a baseline . Too difficult to understand the data . Not cost justified . Cannot detect planet section issues …..All condition monitoring is the same
Bachmann electronic GmbHWind FACTS V2.2 CPM 0 20,000 40,000 60,000 80,000 100,000 120,000 gRMS 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.003 g37.687 orders48773.234 CPMCursor A: O/All 0.243 g RMS Turbine 18 HS Gbx Bearing Vertical [Tach] Demod Spec (2-10kHz) 120000 CPM 8/17/2009 8:09:43 AM O/All 0.243 g RMS Turbine 19 high Speed Vertical Demod Spec (2-10kHz) 120000 CPM 8/17/2009 8:09:24 AM O/All 0.03 g RMS QJ328BPFI QJ328BPFI QJ328BPFI QJ328BPFI HIGH SPEED SHAFT (HSS) $300,000 spectrum
Bachmann electronic GmbH GENERATOR BEARING, $95k spectrum
Bachmann electronic GmbH EPRI REPORT COST JUSTIFICATIONS
Bachmann electronic GmbH CONDITION MONITORING MYTHS . Need lots of data, lots of measurements, with a baseline . Too difficult to understand the data . Not cost justified . Cannot detect planet section issues …..All condition monitoring is the same
Bachmann electronic GmbH PLANET GEAR BEARING
Bachmann electronic GmbH PLANET GEAR
Bachmann electronic GmbH PLANET SECTION
Bachmann electronic GmbH PLANET GEAR
Bachmann electronic GmbH CONDITION MONITORING MYTHS . Need lots of data, lots of measurements, with a baseline . Too difficult to understand the data . Not cost justified . Cannot detect planet section issues …..All condition monitoring is the same
Bachmann electronic GmbH +/- 20% ACCURACY
Bachmann electronic GmbH 60 RPM + 12 RPM +
Bachmann electronic GmbH +/- 20% ACCURACY BOTH ARE CURRENTLY BEING INSTALLED WITH OEM CONDITION MONITORING SYSTEMS WRONG SENSORS +/- 20% ACCURACY USING HIGH SPEED SENSOR IN LOW SPEED LOCATION
Bachmann electronic GmbH CONDITION MONITORING MYTHS . Need lots of data, lots of measurements, with a baseline . Too difficult to understand the data . Not cost justified . Cannot detect planet section issues …..All condition monitoring is the same
Bachmann electronic GmbH TRENDING EXAMPLES
Bachmann electronic GmbH 6/11 warning 8/26 Replacement of the gearbox 1/8 alarm planetary stage
Bachmann electronic GmbH 2/3 warning 5/13 Replacement of the bearing 2/17 alarm HSS bearing
Bachmann electronic GmbH
DAVID CLARK d.clark@bachmann.info

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David Clark: 2013 Sandia National Laboratoies Wind Plant Reliability Workshop

  • 1. Bachmann electronic GmbH CONDITION MONITORING OF THE DRIVE TRAIN MYTHS end of warranty and permanent installations - David Clark
  • 2. Bachmann electronic GmbH WHAT WILL FAIL? AVERAGE SIZE 1.5-2.5MW
  • 3. Bachmann electronic GmbH WHAT WILL FAIL AT EACH SENSOR LOCATION?
  • 4. Bachmann electronic GmbH  TURBINE GEARBOX COMMON INSPECTION TECHNIQUES Component detection percentages on a typical gearbox  VISUAL INSPECTION BORESCOPE INSPECTION VIBRATION ANALYSIS   High Speed Pinion 50% 50% 100%  Intermediate Wheel & Pinion 100% n/a† 100%  Low-Speed Wheel 100% n/a† 100%  Sun Gear No 30%§ 100%  Planetary Gears (3) 10% 30%§ 100%  Ring Gear 20% 30% 100%  High Speed Bearings (3) No 100% 100%  Intermediate Bearings (2-3) No 50%‡ 100%  Low Speed Bearings (2) No 50%‡ 100%  Planetary Carrier Bearings (2) No 30%§ 100%  Planetary Gear Bearings  (6 drCRB) No 30%§ 100%  † Clearly visible during visual inspection by removal of inspection cover  ‡ Depends upon gearbox make/model, oil level and bearing configuration  § Requires several rotations of rotor and to inspect 100%, adding several hours to inspection  By Don Roberts and David Clark
  • 5. Bachmann electronic GmbH DIFFERENT TYPES OF VIBRATION UNITS- Velocity, acceleration, displacement, demodulated/enveloped, time waveform, overall. TIME WAVEFORM VIBRATION SPECTRUM FFT
  • 6. Bachmann electronic GmbH CONDITION MONITORING MYTHS . Need lots of data, lots of measurements, with a baseline . Too difficult to understand the data . Not cost justified . Cannot detect planet section issues …..All condition monitoring is the same
  • 7. Bachmann electronic GmbH FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz 30/04/2004 2:14:30 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/All 0.991 g rms 30/04/2004 2:14:30 p.m. O/All 0.991 g rms <set RPM> FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz 7/07/2004 5:04:47 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/All 0.468 g rms 7/07/2004 5:04:47 p.m. O/All 0.468 g rms <set RPM> RING GEAR
  • 8. Bachmann electronic GmbH FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz 7/07/2004 5:04:47 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/All 0.468 g rms 7/07/2004 5:04:47 p.m. O/All 0.468 g rms <set RPM> FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz 30/04/2004 2:14:30 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/All 0.991 g rms 30/04/2004 2:14:30 p.m. O/All 0.991 g rms <set RPM>
  • 9. Bachmann electronic GmbH HIGH SPEED SECTION (HSS)
  • 10. Bachmann electronic GmbH HIGH SPEED SECTION (HSS) secs 0 1 2 3 4 5 6 7 8 g -0.8 -0.6 -0.4-0.4 -0.2 0 0.2 0.4 0.6 O/All 0.062 g RMS Machine Note (3/8/2010 11:09:42 AM) Changed to High RPM recording 3-8-10 RK T03 Gbx HighSpeed Horizontal [Tach] Acc Wfm 8000 ms 6/23/2011 8:03:10 AM O/All 0.062 g RMS 1802.787 RPM T04 Gbx HighSpeed Horizontal [Tach] Acc Wfm 8000 ms 3/14/2011 3:18:04 PM O/All 0.23 g RMS 1829.291 RPM
  • 11. Bachmann electronic GmbH PLANETARY SECTION secs 0 10 20 30 40 50 60 g -1 0 1 2 3 4 O/All 0.312 g RMS Machine Note (3/8/2010 11:09:31 AM) Changed to High RPM recording 3-8-10 RK T04 Gbx Planetary Horizontal [Tach] Acc Wfm 64000 ms 3/14/2011 3:10:40 PM O/All 0.312 g RMS 20.484 RPM T03 Gbx Planetary Horizontal [Tach] Acc Wfm 64000 ms 6/23/2011 8:10:43 AM O/All 0.035 g RMS 20.297 RPM
  • 12. Bachmann electronic GmbH CONDITION MONITORING MYTHS . Need lots of data, lots of measurements, with a baseline . Too difficult to understand the data . Not cost justified . Cannot detect planet section issues …..All condition monitoring is the same
  • 13. Bachmann electronic GmbHWind FACTS V2.2 CPM 0 20,000 40,000 60,000 80,000 100,000 120,000 gRMS 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.003 g37.687 orders48773.234 CPMCursor A: O/All 0.243 g RMS Turbine 18 HS Gbx Bearing Vertical [Tach] Demod Spec (2-10kHz) 120000 CPM 8/17/2009 8:09:43 AM O/All 0.243 g RMS Turbine 19 high Speed Vertical Demod Spec (2-10kHz) 120000 CPM 8/17/2009 8:09:24 AM O/All 0.03 g RMS QJ328BPFI QJ328BPFI QJ328BPFI QJ328BPFI HIGH SPEED SHAFT (HSS) $300,000 spectrum
  • 14. Bachmann electronic GmbH GENERATOR BEARING, $95k spectrum
  • 15. Bachmann electronic GmbH EPRI REPORT COST JUSTIFICATIONS
  • 16. Bachmann electronic GmbH CONDITION MONITORING MYTHS . Need lots of data, lots of measurements, with a baseline . Too difficult to understand the data . Not cost justified . Cannot detect planet section issues …..All condition monitoring is the same
  • 21. Bachmann electronic GmbH CONDITION MONITORING MYTHS . Need lots of data, lots of measurements, with a baseline . Too difficult to understand the data . Not cost justified . Cannot detect planet section issues …..All condition monitoring is the same
  • 23. Bachmann electronic GmbH 60 RPM + 12 RPM +
  • 24. Bachmann electronic GmbH +/- 20% ACCURACY BOTH ARE CURRENTLY BEING INSTALLED WITH OEM CONDITION MONITORING SYSTEMS WRONG SENSORS +/- 20% ACCURACY USING HIGH SPEED SENSOR IN LOW SPEED LOCATION
  • 25. Bachmann electronic GmbH CONDITION MONITORING MYTHS . Need lots of data, lots of measurements, with a baseline . Too difficult to understand the data . Not cost justified . Cannot detect planet section issues …..All condition monitoring is the same
  • 27. Bachmann electronic GmbH 6/11 warning 8/26 Replacement of the gearbox 1/8 alarm planetary stage
  • 28. Bachmann electronic GmbH 2/3 warning 5/13 Replacement of the bearing 2/17 alarm HSS bearing