Data driven predictive maintenance strategy - … · Data driven predictive maintenance strategy...
Transcript of Data driven predictive maintenance strategy - … · Data driven predictive maintenance strategy...
Data driven predictive
maintenance strategy
IEA Wind Task 33 Workshop
Dr Robin Elliott, Senior Consultant
23rd September 2015
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Romax Technology
• Gearbox and drivetrain specialists
• Established in 1989
• Approx. 220 employees globally, 120
in UK, 12 offices worldwide
• Work in a range of industries
o Wind energy
o Automotive, heavy industry,
marine, aerospace
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Romax Technology
InSight health management solutions, predictive
maintenance software and services, independent engineering, due
diligence
Drivetrain and gearbox design, worldwide no. 1
independent wind turbine gearbox designer; 39 certified gearbox
designs to date
Drivetrain simulation, RomaxWIND virtual product
development environment; dynamic analysis and bearing
simulation
Engineering consultancy and fleet services, inspections,
analysis, certification support, failure investigation
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Engineering track record
• Romax has assessed the performance
and health of over 10 GW of wind
turbines across 4 continents
• Over 40% of the UK offshore fleet is
currently monitored by Romax
• Acciona, Bonus, Clipper, De Wind,
Gamesa, GE, Mitsubishi, NEG-Micon,
Nordex, Senvion, Siemens, Sinovel,
Suzlon, Vestas, etc.
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Contents
• Combining data sources in a single software platform to enable
predictive maintenance
• Maximising up-front data analysis to aid inspections and
maintenance
• Collecting consistent failure data through standardised
inspection routines and reporting
• Other examples of usage of reliability data
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Combining data sources in a single software platform to
enable predictive maintenance
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Fleet Monitor software
• Hardware-independent wind turbine monitoring solution
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CMS (Bently Nevada,
Commtest, SMP, etc.)
Wind farm 1
(e.g. Siemens, Vestas, etc.)
Romax server
‘Hardware independent’ condition monitoring
Romax monitoring
service
Fleet MonitorTM
software
Wind farm 2 (e.g.
GE, Gamesa, Clipper, etc.)
Database or
site server
Database or
site server
CMS (Gram & Juhl
TCM, B&K Vibro, etc.)
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Assessing machinery health using vibration, inspection
and oil analysis
Increasing
vibration
trend triggers
inspectionHigh Fe content
in oil analysis
report
Inspection
report logged in
Fleet Monitor
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Maximising up-front data analysis to aid inspections and
maintenance
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Up-front data analysis
Determine likely targets
before inspections:
• Detailed SCADA and CMS
analysis
• Detailed review of
previous failure types and
timescales
• Issues often fixed with
gearbox modifications –
which are fitted?
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Collecting consistent failure data through standardised
inspection routines and reporting
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Collecting consistent failure dataStandardised inspection routines and reporting
At what point has a
component ‘failed’?
• Consistent, objective criteria
• Consistently reported
• Romax have developed an
app for phones / tablets
• Directs and simplifies
inspections
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Collecting consistent failure dataStandardised inspection routines and reporting
• Detailed failure data helps
direct inspections
o E.g. if planetary bearings are
prone to cracking, inspect more
of each race
o Spend more time where
necessary
• Results immediately sent back
to Romax
o Serial issues can quickly be
identified
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Failure data example – main bearing failure
• CMS has detected a bearing issue – do I need to replace it? And when?
• Micropitting is often the first step in the failure of the bearing
• The debris generated leads to macropitting and a run-away surface fatigue condition
• Deterioration can be slowed, e.g. by grease flushing
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Failure data example – main bearing failure
• Typical main bearing failure modes detected by CMS:
Severe outer race macropitting and cracking
Roller macropitting
Severe roller damage Inner race macropitting
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Failure data example – main bearing failure
• Typical main bearing fault development over a long time period:
First Romax Alarm
8.5 months
Bearing
Replaced
Main
Beari
ng
Healt
h I
nd
ex
Date
• Recording the damage
level over time enables
statistical estimates of
remaining life
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Failure data example – main bearing failure
• Time from fault detection by CMS to main
bearing failure ranges from ~2 months to
~2 years
• P50 time to failure for this particular
bearing type and failure mode is ~1 year
from fault detection
• Correlation of failure data with CMS data
improves maintenance planning – can
reduce the cost of major replacements!
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Failure data example - due diligence
• Turbine technology review
o Reduce uncertainty in availability,
power production, failure rates and
O&M cost forecasts
o Turbine historical performance –
benchmarking against global portfolio
o O&M costs and mitigation strategies
o Reliability forecasts, Weibull analysis
o Review of operational agreements,
warranty risks
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Failure data example - due diligence
• Site specific/turbine specific
O&M cost forecasts
• Analysis of cost scenarios –
P90, P50, O&M service
providers, equipment
upgrades, etc.
• Financial model review
• Analysis of power production,
availability and downtime
• Independent Engineering
support for contract
negotiations
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Asset life extension
• Life extension for 20+ years
• Evaluating asset’s value
approaching the end of useful life
• Operational expenditures vs. power
generation scenarios
• Life extension strategy
• ‘Repower’ decision support
(expected revenue, operational
statistics)
Loads• Designed/predicted loads
• Measured loads
Simulation• Tuned models to predict
asset’s useful life
Cost impact
calculation
• O&M cost
forecast
• Revenue
forecast
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Summary
• Romax is an ISP to turbine manufacturers, wind farm owners, operators
and financial sector
• Good reliability data is essential to reduce CoE through:
oMore robust design
oReduced cost of Operations and Maintenance through predictive methodologies
oBetter service contracts
oReduced insurance premiums
oLife extension