Chuck Jenkins: 2013 Sandia National Laboratoies Wind Plant Reliability Workshop
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Transcript of Chuck Jenkins: 2013 Sandia National Laboratoies Wind Plant Reliability Workshop
Bently Nevada Wind CMS Offerings
Oil & Gas Power Generation
• Thermal• CCPP• Co-Gen• Hydro• Wind
• LNG• Ethylene• Refining• Fertilizers• PTA
Who is Bently Nevada?
Switch/Hub
Rotating Machines
Online - Continuousmonitoring & protection
3500 & TDI
Online – Periodic(scanning) monitoring
Wired Wireless
Essential Assets• Fans
• Pumps
• Blowers
• Etc…
SCOUT 100
BOP Assets• Vibration
• Portable Devices
• Lube Oil
• Thermography
• MCA, etc…
Offline – Periodic walk-around monitoring
Critical Assets• Gas Turbines
• Steam Turbines
• Compressors
• Main line Pumps
Bently Nevada – Online Condition Monitoring
Why Plant Asset Optimization?
Optimization of plant asset performance and reliability is essential to meeting the challenge of increased production at lower costs - a situation
faced by many companies in a world of increased competition
Improved:• Safety, environmental compliance• Reliability, availability• Throughput, quality• Planning and scheduling• Maintenance efficiency• Spare parts inventory
Reduced:• Downtime• Energy consumption• Maintenance costs Plant Asset Optimization
Wind Farm Operators strive to optimize their maintenance resources by minimizing down-tower repairs & making sure parts are on hand Graphic from EPRI Paper – Condition Monitoring of Wind Turbines
What are the business challenges?
Benefits of Early Detection
• Limit downtower repairs
• Eliminate expedited crane charges
• Crane bundling to minimize mobilization and demobilization charges
• Minimize downtime and optimize planning for low wind repairs
“25%-30% of the overall operation and maintenance costs at a wind farm will be associated with the gearbox alone.”*
*EPRI Paper – Condition Monitoring of Wind Turbines
Why Drive Train CMS?
Failure Rates, Costs, and CMS Value
Component Failure Rate Total Cost Detection Rate (%)
Savings From CMS
Total Savings
Gearbox 3% $255,240 50% $80,000 $1,200
GearboxRefurbishment
38% $200,240 50% $80,000 $15,200
Generator 5% $146,280 80% $30,000 $1,200
Main Bearing 18% $135,240 40% $20,000 $1,440
Generator Refurbishment
10% $113,280 80% $30,000 $2,400
Gearbox Stage Replacement
35% $40,760 50% $10,000 $1,750
Average Savings from CMS: $23,190 per turbine
Bently Nevada Wind CMS Offerings
Entered Market with DSM Solution
~ 25 Units installed
2004 2006 2008 2009 2012 +
Refine Wind solution: Independent
processor/Scalable ADAPT. Wind Released
Continuous Product
Enhancements
DSM Solution ~ 25 Units installed
TurningPoint ~ 2000 Units installed
SmartSignal ~ 150 Units installed
ADAPT.Wind ~ 3000 Units installed
ADAPT.Wind - Standard Option for GE New Units & Included in LTSA
Condition Monitoring System
Drivetrain TransducersUp-Tower
SoftwareMonitorUp-Tower
Network Friendly Architecture
Monitors communicate with the farm server via the SCADA Network.
Utility Transmission System
SCADA Server Local ADAPT Server
Firewall
SCADA Network
Remote Monitoring Center
WAN
Expandability
Farm Server
• Bently Nevada Data Services• ADAPT.wind Farm Client or Ascent
WTG1 Monitor
WTG2 Monitor
WTG199 Monitor
WTG200 Monitor
One farm server can accommodate up to 200 Wind Turbine Generator (WTG) monitors.
SCADA Network
WTG3 through WTG198
Ethernet Switch
Transducer Locations
Ring Gear
Sun Gear
Planet Gear
Rotor Hub
HSS
HSIS
LSIS
Generator
Gearbox
HSS Speed
LSS Speed
LSS
Main Bearing
Intermediate Stage
Planetary Stage
High Speed Stage
Generator Bearings
6 accelerometers
2 speed sensors
Powerful Calculation Engine
• Calculation engine embedded inside the monitor• Patented Algorithms – DEI & SER• Up to 200 trendable variables
• Component specific variables for the main bearing, generator, and gearbox
• Available as input into SmartSignal Predictive Analytics• Data is stored, trended, and alarmed.
Powerful Diagnostics
Sensor Health– Transducer Bias Voltage
Broadband– Direct Peak Amplitude– Direct RMS Amplitude– Crest Factor– Kurtosis– Cumulative Impulse (CI)
Spectral Bands– Orders-Based Amplitude– Dynamic Energy Index (DEI)– Enveloped (demodulated)
Bearing Fault Frequencies– Gearmesh Frequencies– Gearbox Fault Frequencies
• Planet Fault (3X LSS), Ring Fault, Sun Fault, etc.
These measurements are processed by the 3701/60 monitor.
ADAPT.Wind calculated variables
•Advanced Techniques• Planetary Impulse Detection (particle trend)
Cumulative Impulse CountCumulative Impulse RateCumulative Impulse Magnitude
• DEI Dynamic Energy Index…Specifically designed for variable speed machines.
• Kurtosis
4.538 4.54 4.542 4.544 4.546 4.548 4.55 4.5520
1
2
3
4
5
6
7
8
Time (s)
g
SlavePlanetaryRotor16Apr10second1; corner = 0.1 Hz; order 2; 13 events for DI = 66 GE CONFIDENTIAL
Planetary debris passage detection by cumulative impulse calculations
AmplitudeResets
AdaptiveThreshold(12 x LP signal)
Low-pass filtered signal (red)
DecayEnvelope
Final Maximum For Event (red dot)
RectifiedSignal
EventTerminationEvent
Start
DefaultThreshold4 g
Dynamic Energy Index (DEI) Bands - Definition
Spectral Energy is summed within Discrete Frequency Bands shown here, where the Bands correspond to gearbox components.DEI Variables are normalized by Torque
Variable Frequency Range Description
DEI Bearing 0 – 25 Hz L.S. shaft bearings, Planet bearings, all rotor-related frequencies
DEI Planetary 28 – 130 Hz Planetary Gear Mesh Frequencies
DEI Intermediate 145 – 570 Hz Intermediate gear mesh frequencies
DEI High 590 – 3300 Hz High Speed gear mesh frequencies
DEI Structural 4000 – 10000 Hz Covers structural resonant frequencies which are excited by mechanical impacts
DEI Bands
New Healthy Gearbox
Same Gearbox After HALT damage
Damaged Gearbox
NewGB
DamagedGB Ratio
DEI Bearing 3.95E-06 4.75E-04 120.1DEI Planetary 4.39E-04 1.00E-02 22.9DEI Intermediate 5.37E-04 3.36E-02 62.6DEI High Speed 1.21E-02 4.47E-01 37.1DEI Structural 3.60E-02 5.63E+00 156.4
DEI Test values:
DEI Bands – Overlaid on actual Frequency Spectrums comparing the gearbox vibration signature of the same gearbox at the beginning and end of a HALT test.
Kurtosis
•Variance (standard deviation squared) involves the square of differences between data and the mean•Variance is the 2nd moment•Skew is the 3rd moment
•Kurtosis is the 4th moment. It puts more emphasis on the tails of the distribution
•Spikier waveforms have higher Kurtosis
Planetary Sun Gear Failure
Background>Vibration increased in planetary stage>ADAPT showed high overall vibration and defect on
sun gear
Benefits …
>Two weeks advanced notice>Confirmed crane mobilization required>Confirmed gearbox replacement required
Generator Drive End Bearing EDM
Damage
Corrosion
Spectrum Waterfall –shows signs of bearing EDM (electrical discharge machining) progressing rapidly.
Bearing Inner Race and Sidebands
Spectrum Detail – shows repeating harmonic peaks of ORBP (Outer Race Ball Pass) frequency, a classic sign of EDM.
Harmonics with Sidebands
Generator Drive End Bearing EDM
• Ensures proper generator slip-ring operation
• Uptower repair
• Early detection of EDM allows corrective action to be taken prior to significant bearing damage occurring
Cost Saving Examples – Bearing Cracks
• Reduced secondary damage
• Uptower repair
• Trending allows for maintenance during maintenance or low winds
Broken HSIS Pinion Tooth (Sideband Energy Ratio)
SER = 1.1SER = 3.9 SER = 5.6
Questions?