REWITEC Additives to Extend Gearbox Life

REWITEC Additives to Extend Gearbox Life

Wesley ThomasVice President, Major Accounts

© 2016 Sentient Science Corporation – Confidential & Proprietary

REWITEC Engagement Summary

Business Challenge to Solve: Project Objective:

WindEurope 2017 - REWITEC Additives to Extend Gearbox Life

Operators seeking to extend the life of GE 1.5MW Winergy 4410.2 GBXs that are slightly damaged

Develop DigitalClone prognostic model to

quantify the effect of REWITEC DuraGear

W100 treatment of GE 1.5 Winergy 4410

Predict and compare the fatigue performance of

“As Is” components with “To Be” components

with surface roughness inputs from REWITEC

Step 1:

Transfer of Data and Materials

Step 2:

Load Analysis for Winergy 4410.2 GBX

Step 3:

Bearing and Gear Material Model Development

Step 4:

DigitalClone Simulation for Bearings & Gears

Step 5:

GBX Life Extension for Winergy 4410.2 with

DuraGear W100 Treatment

Step 6:

Final Report & Recommendation

Why We Chose GE 1.5MW as Example Case Study

REWITEC seeking to enter U.S. Aftermarket

Successful deployments in Europe

GE 1.5MW chosen as ideal platform for US


Technical Step 1 – Transfer of Data and Material

REWITEC Field Trials and Available Data

REWITEC had extensive testing and field trials and approval by GE to be used in after warranty turbines

REWITEC had the correct inputs measured during the field trials that are inputs into the DigitalClone modeling process


Technical Step 1 – Transfer of Data and Material

REWITEC Test Details for Bearings Roughness Input to DigitalClone Simulation

• FE-8 Test at University Mannheim

• Roughness Analyses by NanoFocus AG

• Test run at load of 80 kN for 80 Hrs

• Surface roughness and weight loss was analyzed after 80 Hrs


FE-8 Test – Gear Oil

Case Study - Apache Spiral Bevel Gear Validation

Example of Previous Validation by Sentient to Evaluate Surface Finish

Sentient results matched the Boeing rotorcraft gear design life under loading conditions equivalent to those experienced during the qualification testing

DigitalClone assists in increasing the gearbox ratings


Load

Case

Weibull,

Life/Eta

Weibull,

Slope

300 HP Run-out Run-out

1021 HP 5.14E+07 1.72

1379 HP 1.26E+07 3.32

2042 HP 7.49E+06 3.84

1731 HP 2.97E+06 4.28

Surface stress = -1200 MPa

Surface stress = -1000 MPa

1E+6 4E+6

Technical Step 2 – Gearbox Load Analysis

DigitalClone System and Component Models

Multi-body Dynamics system model was created in Modelica that translates forces from the hub to the individual components.

Wind loads are being applied on DigitalClone MBD system model to calculate global forces and moments on individual components.


Multi-body Dynamics (MBD)

GBX Loads and Life

Forces and

Moments

Wind Turbine Operational Data

BOM

Oil Properties

Geometry& Configuration

GBX Prognostic Model

Technical Step 3 – Material Model Development

Based on Winergy 4410.2 Material Analysis

To obtain the following technical details from gears and bearing segments as inputs for DigitalClone Model

• Grain size and morphology

• Case microstructure, core microstructure, case-core transition region microstructure

• Defects, non-metallic inclusions size distribution, if any

• Material imperfections, retained austenite, grind burn etc.

• Residual stress analysis

• Surface roughness analysis


EDM Sectioned Bearing Segment

Technical Step 4 – Mixed EHL Model

Lubrication Testing & Surface Treatment


Technical Step 5 – DigitalClone Life Simulation


Intermediate Pinion Gear – at 1.5MW rated Power

Contact Stress 1.7 GPa

L10 Life Operational

Hrs


Hrs


Hrs“As Is” 4,239.70 5.58E+05 1.66E+07

Rewitec “To Be” 54,871.61 8.89E+07 1.06E+10Life

Improvement 12.9 159.3 633.8

“To Be”

“As Is”

“To Be”

“As Is”

High Speed IMS Bearing DW– Inner Race at 1.5MW rated Power

Ge 1.5 SLE Winergy 4410.2 HSIS DW bearing life (L10) improved by a factor of 12.9 with Rewitec treatment (“To Be”)

Contact Stress L10 Life

Operational Hrs


Hrs


Hrs“As Is” 787.7 2,678.1 27,443.9

Rewitec “To Be” 1,405.0 9,928.8 66,809.7Life

Improvement 1.8 3.7 2.4

Technical Step 6 – Life Results


Winergy 4410.2 GBX Life Extension using DuraGear W100

WindEurope 2017 - Introducing DigitalClone Live

The REWITEC DigitalClone model can be applied to the fleet to determine life

extension across specific assets in the fleet

WindEurope 2017 -REWITEC Additives to Extend Gearbox Life


WindEurope 2017 -REWITEC Additives to Extend Gearbox Life

Trade-Off Studies Asset/Customer specific trade-off option to confidently

predict impact on life/ROI (e.g. gearbox replacements)

ROI Optimization

All trade-offs based

on ROI at the

individual asset

level/group,

maximizing ROI for

the fleet.

REWITEC Upgrades

as Operator Option


Additional Use Cases of REWITEC DigitalClone Model

Apply to Other Gearbox Types (Non GE 1.5MW Winergy 4410)


Supplier 1Supplier 2Supplier 3Supplier 4

Supplier 1Supplier 2Supplier 3Supplier 4

5 years 10 years 15 years 20 years



Apply to Other Gearbox Types (Vestas, Siemens, Acciona, Gamesa Turbines)


Gearbox

Winergy 4435

Winergy 4456

Hansen EH 802

Hansen EH 804

Moventas PLH

GPV 442

Turbine

Siemens 2.3MW

Vestas V82

Vestas V90

Vestas V80

Siemens 3.6MW

Acciona 1.5MW



How Much Can REWITEC Grease Extend Main Bearing Life?


Sentient case study provided a low cost solution by improving main bearing L10 fatigue life to

avoid premature failures by changing to better lubricant and implementing superfinish

Opportunity to evaluate REWITEC grease3 Parameter Weibull Reliability Analysis

L10 Life L15 Life L17 Life

Conservative

Case

Best

Case

Conservative

Case

Best

Case

Conservative

Case

Best

Case

Baseline 7.6 yrs. >20 yrs. 15.5 yrs. >20 yrs >20 yrs >20 yrs

Super Bearing 18.4 yrs. >20 yrs. >20 yrs. >20 yrs. >20 yrs. >20 yrs.

Overall, L10 fatigue life improved by a factor of 2.42 for Sentient recommended bearing configuration



OEMs/ISPs Service/Warranty Optimization and New GBX Upgrades


OEM Fleets under LTSA’s

End of Warranty Management

Alternative to Superfinish for new upgrades and gearboxes



OEMs/ISPs Service/Warranty Optimization and New GBX Upgrades


DCL identifying failure risk and risk exposure for operators when they are weighing their insurance

contracts and other risk management tools

Reduce Gearbox Failure Rates and Risk Exposure – Translate to Lower Premiums for Owner

Operators

Data Driven Forecast Year 5

Under Budget

Unknown Risk

No Corrective Actions

Cu

mu

lati

ve f

ailu

re r

ate

Time

Material Driven Forecast Year 5

On Budget

Forecasted Risk

Take Corrective Actions

Cu

mu

lati

ve f

ailu

re r

ate

Time

Real Future Failure Rate

Forecast

Historical Data

New Failure Rate

Forecast

Historical Data

Executive Summary

Sentient Science has a long history of life extension modeling within aerospace and wind turbine industries for owner-operators

We have helped our wind turbine owner-operator customers identify critical drivers of gearbox failures, and they have mandated us to deliver how many will fail, what should they replace it with, and put them in touch with new life extension solutions

REWITEC reached Sentient Science to evaluate how to enter the U.S. wind market after much field trial and testing in EU and China. Sentient Science life extension study showed 2x-3.3x improvement.

Opportunities for operators to evaluate ROI on their assets


Thank you! Learn More and Meet the Team!

Sentient Presentation Schedule WindEurope 2017

1. Introducing DigitalClone Live

2. Duke Energy Case Study

3. Main Bearing RCA

4. How to Value Digitalization

5. DigitalClone Live Product Update

6. Why Data Science Alone Wont Lower the Cost of Energy

7. Moventas XL Life Extension Program

9. Rewitec Additives to Extend Gearbox Life

10. DigitalClone Bearing Product Release

11. Wind Loads Modeling

12. Data Fusion: Material Science & Data Science

13. Drivetrain Modeling

14. Reducing Costs with Digitalization

WindEurope 2017 - Introducing DigitalClone Live

REWITEC Additives to Extend Gearbox Life

Engineering

Transcript of REWITEC Additives to Extend Gearbox Life