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Investigation of Various Wind Turbine Drivetrain Condition Monitoring Techniques

Shawn Sheng Senior Engineer, NREL/NWTC Wind Turbine Condition Monitoring Workshop October 8-9 2009

NREL is a national laboratory of the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy operated by the Alliance for Sustainable Energy, LLC

Outline ƒ Introduction ƒ Drivetrain condition monitoring (CM) • • •

Approach Rationale Implementation

ƒ Preliminary results

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Introduction: Subsytem Down Time Wind Stats: 2003-2006 Stop Hours per Turbine Subsystem 70000 65000 60000 55000 50000

Stop Hours

45000 40000 35000 30000 25000 20000 15000 10000 5000 Sensors

Hydraulics

Elec. System

Elec. Controls

Windvane/anemometer

Yaw System

Generator

Gearbox

Main shaft/bearing

Pitch Adjust.

Mech. Brake

Air Brake

Rotor

0

ƒ Need to reduce drivetrain down time: replace traditional time-intervalbased maintenance with conditionbased maintenance (CBM) Credit : Francisco Oyague

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Introduction: Condition Monitoring ƒ One information source to achieve CBM: Condition Monitoring (CM) ƒ Benefits of CM: • Early deterioration detection can avoid catastrophic failure • Accurate evaluation of damage will enable costeffective maintenance planning • Root-cause analysis can improve operational strategy • Increased turbine operational hours

Credit : Chris Walford and Don Roberts, EPRI Report National Renewable Energy Laboratory

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Gearbox Reliability Collaborative (GRC) ƒ Two identical test gearboxes: one for dynamometer and the other for field test ƒ Dynamics measurement: more than 120 channels of internal instrumentation ƒ CM: both dynamometer and field tests National Renewable Energy Laboratory

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Drivetrain CM: Approach & Rationale ƒ Approach • A combination of acoustic emission (specifically stress wave), vibration and lubricant CM techniques.

ƒ Rationale • Each technique has its own strengths and limitations.

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Dynamics CM: Implementation ƒ SwanTech • One of the few commercial packages using ultrasonic range signals for CM • CM experience in wind industry.

ƒ SKF

Source: SwanTech (with permission)

• One of the best vibration CM systems among interested participants • Huge bearing database benefited from being a main bearing supplier to wind turbines • CM experience in wind industry. Source: SKF (with permission) National Renewable Energy Laboratory

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Oil CM: Implementation ƒ Kittiwake • Multiple parameters obtained by one compact package • No limitation on flow rates.

ƒ Macom

Source: Kittiwake (with permission)

• Five bins of both ferrous and nonferrous particle sizes • Flow rate matches the kidney loop specifications.

ƒ Hydac

Source: Macom (with permission)

Source: Hydac (with permission)

• Provide ISO 4406 cleanliness level readings • Experience with lubricant Castrol OptiGear X320. National Renewable Energy Laboratory

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Dynamometer Test Implementation ƒ Periodic oil sample analysis: •

Obtain information not provided by oil CM systems and correlate with oil CM system readings.

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Field Implementation

For both dynamometer and field tests, most CM data is remotely accessible using a web browser

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Preliminary Results: Vibration (Dyno) ƒ Capable of detecting: • gear mesh, shaft rotational, bearing characteristic frequencies. ƒ Trending of these frequencies : • changes in condition of monitored components (e.g., bearing). National Renewable Energy Laboratory

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Preliminary Results: Stress Wave (Dyno) ƒ Two pairs of strong correlations: • rpm with SWE at main bearing and generator • Dyno motor power and SWE at ring/helical gears.

ƒ SWE might be useful for inferring driving load to the gearbox, if measurement is not available. National Renewable Energy Laboratory

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Preliminary Results: Oil ƒ A broad range of particles generated: • all three bins • wind turbine gearboxes always emit particles.

ƒ Contamination level: • increases with ramping up of generator speed • decreases with shutdown of the generator and a continuously functional lubricant filtration system • might be useful as an indictor for run-in of gearboxes.

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Preliminary Results: Oil (Cont.)

ƒ Other oil CM systems: • No subtle changes: might be designed for long-term operations, not applicable for run-in. National Renewable Energy Laboratory

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Vibration (Field) : Speed Trends

Credit : SKF National Renewable Energy Laboratory

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Generator Bearing DE and NDE Trends

Credit : SKF National Renewable Energy Laboratory

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Generator DE Enveloping

Abnormal cage and ball spinning frequencies observed Credit : SKF National Renewable Energy Laboratory

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Stress Wave (Field) : Generator DE

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Oil CM (Field)

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Lessons Learned So far ƒ Each technique has its own pros and cons ƒ Confidence in diagnostics can be increased by fusing different techniques, typically oil with vibration or acoustic emission ƒ Data interpretation is critical for achieving correct diagnostics results and subsequently appropriate O&M strategies ƒ Fully automatic action recommendation from online CM systems appears challenging

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Thank you!

NOTICE: This presentation was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof.

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