David Clark: 2013 Sandia National Laboratoies Wind Plant Reliability Workshop

Bachmann electronic GmbH

CONDITION MONITORING OF THE DRIVE TRAIN MYTHS

end of warranty and permanent installations

- David Clark


WHAT WILL FAIL? AVERAGE SIZE 1.5-2.5MW


WHAT WILL FAIL AT EACH SENSOR LOCATION?


TURBINE GEARBOX COMMON INSPECTION TECHNIQUESComponent 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


DIFFERENT TYPES OF VIBRATION UNITS- Velocity, acceleration, displacement, demodulated/enveloped, time waveform, overall.

TIME WAVEFORM VIBRATION SPECTRUM

FFT


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


FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz30/04/2004 2:14:30 p.m.

Hz0 200 400 600 800 1,000 1,20

g rm

s

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7O/All 0.991 g rms

30/04/2004 2:14:30 p.m. O/All 0.991 g rms <set RPM>


Hz0 200 400 600 800 1,000 1,20

g rm

s

0

0.1

0.2

0.3

0.4

0.5

0.6



RING GEAR



Hz0 200 400 600 800 1,000 1,20

g rm

s

0

0.1

0.2

0.3

0.4

0.5

0.6




Hz0 200 400 600 800 1,000 1,20

g rm

s

0

0.1

0.2

0.3

0.4

0.5

0.6




HIGH SPEED SECTION (HSS)


HIGH SPEED SECTION (HSS)

secs0 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 RPMT04 Gbx HighSpeed Horizontal [Tach] Acc Wfm 8000 ms 3/14/2011 3:18:04 PM O/All 0.23 g RMS 1829.291 RPM


PLANETARY SECTION

secs0 10 20 30 40 50 60

g

-1

0

1

2

3

4O/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 RPMT03 Gbx Planetary Horizontal [Tach] Acc Wfm 64000 ms 6/23/2011 8:10:43 AM O/All 0.035 g RMS 20.297 RPM



. Need lots of data, lots of measurements,with a baseline





Bachmann electronic GmbHWind FACTS V2.2

CPM0 20,000 40,000 60,000 80,000 100,000 120,000

g RM

S

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 RMSTurbine 19 high Speed Vertical Demod Spec (2-10kHz) 120000 CPM 8/17/2009 8:09:24 AM O/All 0.03 g RMS

QJ3

28 B

PFI

QJ3

28 B

PFI

QJ3

28 B

PFI

QJ3

28 B

PFI

HIGH SPEED SHAFT (HSS) $300,000 spectrum


GENERATOR BEARING, $95k spectrum


EPRI REPORT COST JUSTIFICATIONS



. Need lots of data, lots of measurements, with a baseline






PLANET GEAR BEARING


PLANET GEAR


PLANET SECTION


PLANET GEAR









+/- 20% ACCURACY


60 RPM +

12 RPM +


+/- 20% ACCURACY

BOTH ARE CURRENTLY BEING INSTALLED WITH OEM CONDITION MONITORING SYSTEMS

WRONG SENSORS

+/- 20% ACCURACYUSING HIGH SPEED SENSOR IN LOW SPEED LOCATION









TRENDING EXAMPLES


6/11 warning

8/26Replacement

of the gearbox1/8

alarm

planetary stage


2/3 warning

5/13Replacement of the bearing

2/17 alarm

HSS bearing


DAVID [email protected]

Business

David Clark: 2013 Sandia National Laboratoies Wind Plant Reliability Workshop