This webinar outlines Sentient's development on their White Etching Crack capabilities to current materials-based prognostics life prediction models to better predict wind turbine gearbox life.
The formation of white etching cracks (WEC's) in bearings are known to be one of the major failure modes associated with gearbox failure. WEC's can casue premature failures in rolling element bearings occuring as early as 1-20% of the calculated L10 life.
According to the National Renewable Energy Laboratory's (NREL) gearbox failure database, 64% of gearboxes failed due to bearings and 25% due to gear failures. These failures are causing increased downtime and costly repairs.
The webinar outlines microstructrual alterations detected in LSIS and HSIS bearings and how microstructural alterations impact damage in gearboxes.
5. SentientScienceCorp.-Proprietary/PrivateLevel1
Why Investigate White Etching Cracks?
Uncertainty
• Conflicting synopsis for why WEC occurs
• WEC is only visible once failure is detected
• Unknown whether White Etch areas are a cause or effect of cracks
Risk
• Currently using sensor vibration data to detect WEC
• 64% of gearbox failure is due to bearings
• WEC’s are known to cause premature failures in rolling element
bearings occurring less than 50% of the design life
Cost
• HSIS bearing could cost up to $20,000 to replace
• Damage to LSS & planetary systems can cost >$100,000 each
• Full gearbox replacement ranges from $200,000 - $500,000
39. SentientScienceCorp.-Proprietary/PrivateLevel1
Why Investigate White Etching Cracks?
Uncertainty
• Conflicting synopsis for why WEC occurs
• WEC is only visible once failure is detected
• Unknown whether White Etch areas are a cause or effect of cracks
Risk
• Currently using sensor vibration data to detect WEC
• 64% of gearbox failure is due to bearings
• WEC’s are known to cause premature failures in rolling element
bearings occurring less than 50% of the design life
Cost
• HSIS bearing could cost up to $20,000 to replace
• Damage to LSS & planetary systems can cost >$100,000 each
• Full gearbox replacement ranges from $200,000 - $500,000
1- We computational model rotating components to understand the life through a material science based approach
2- this allows us to understand prior to failure where a crack is occurring and provide our customers with asset actions to extend the life of their machines
3- Different industries
4-Supplier vs. operator side
Operators are asking us if we have this capability in our model
WEC are causing bearing failures that are increasing Failure risk and O&M spend
No clear answer on why WEC occurs
Risk: Data from an NREL report
Among bearings, the highest number of failures were observed in HSS due to axial cracking and spalling
1- Dr. Harpal Sing will take us through the technical scope of Sentient’s work to predict WEC in their prognostic models
2-Introduce him
.
Risk:
Too late in process failures are already occurring
Today, using sensors to detect WEC related failures
Source NREL
We find a lot of operators are experiencing WEC that are leading to bearing/ gear failure and eventually to drivetrain failures
Sentient is developing a computational model to understand how WEC occurs and the impact it has on the life of the GBX
We will have a secondary webinar to show results once the model is more mature