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

Bachmann electronic GmbH

WHAT WILL FAIL? AVERAGE SIZE 1.5-2.5MW

Bachmann electronic GmbH

WHAT WILL FAIL AT EACH SENSOR LOCATION?

Bachmann electronic GmbH

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

Bachmann electronic GmbH

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

TIME WAVEFORM VIBRATION SPECTRUM

FFT

Bachmann electronic GmbH

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

Bachmann electronic GmbH

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>

FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz7/07/2004 5:04:47 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 0.468 g rms

7/07/2004 5:04:47 p.m. O/All 0.468 g rms <set RPM>

RING GEAR

Bachmann electronic GmbH

FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz7/07/2004 5:04:47 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 0.468 g rms

7/07/2004 5:04:47 p.m. O/All 0.468 g rms <set RPM>

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>

Bachmann electronic GmbH

HIGH SPEED SECTION (HSS)

Bachmann electronic GmbH

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

Bachmann electronic GmbH

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

Bachmann electronic GmbH

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

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

Bachmann electronic GmbH

GENERATOR BEARING, $95k spectrum

Bachmann electronic GmbH

EPRI REPORT COST JUSTIFICATIONS

Bachmann electronic GmbH

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

Bachmann electronic GmbH

PLANET GEAR BEARING

Bachmann electronic GmbH

PLANET GEAR

Bachmann electronic GmbH

PLANET SECTION

Bachmann electronic GmbH

PLANET GEAR

Bachmann electronic GmbH

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

Bachmann electronic GmbH

+/- 20% ACCURACY

Bachmann electronic GmbH

60 RPM +

12 RPM +

Bachmann electronic GmbH

+/- 20% ACCURACY

BOTH ARE CURRENTLY BEING INSTALLED WITH OEM CONDITION MONITORING SYSTEMS

WRONG SENSORS

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

Bachmann electronic GmbH

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

Bachmann electronic GmbH

TRENDING EXAMPLES

Bachmann electronic GmbH

6/11 warning

8/26Replacement

of the gearbox1/8

alarm

planetary stage

Bachmann electronic GmbH

2/3 warning

5/13Replacement of the bearing

2/17 alarm

HSS bearing

Bachmann electronic GmbH

DAVID [email protected]