Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.
Proac&ve	Turbine	Damage	Reduc&on	
-Quan&fying	the	value	of	reducing	Transient	Loads,	
u&lizing	a	life	cost-based	FMEA	appr...
#WindWebinar
q  This webinar will be available afterwards at
www.windpowerengineering.com & email
q  Q&A at the end of the...
#WindWebinar
Michelle Froese
Senior Editor - Moderator
Windpower Engineering
& Development
Dustin Sadler
Principal Enginee...
#WindWebinar
1.  What	is	a	Transient	Torsional	Event?	
2.  How	do	you	mi:gate	damaging	TTEs?	
3.  How	does	this	affect	turb...
#WindWebinar
•  The	data	shows	a	50-70%	
reduc:on	in	the	worst	
loads	from	transient	
torsional	events			
•  The	value	of	...
#WindWebinar
Taming	Torsional	Loads	in	the	World’s	Most	Extreme	Machines	for	37	Years.
#WindWebinar
	
This	is	your	turbine	
making	money!
#WindWebinar
Example:		
Braking	Procedure	
during	a	Hard	Stop	
Normal	Opera&on	
	
Stopping	Protocol	
Triggered	
Combined	A...
#WindWebinar
Any	control	system	reac:on	requiring	rapid	pitching	
and/or	strong	mechanical	braking.
#WindWebinar
	
	
•  E-stops	are	not	the	only	hard	
stops.	
•  E-stops	are	not	the	only	damaging	
type	of	stopping	events.
#WindWebinar
Winds	also	ini:ate	
transient	loads!
#WindWebinar
#WindWebinar
“Reverse	Torsional	Damper”
#WindWebinar
	
1.6	MW	Turbine	
Ini:al	Slip	Event	
Removes	Torsional	
Energy	
1	
50-75%	Reduc:on	
Torsional	Oscilla&ons	
2	...
#WindWebinar
These	loads	
are	not	
unique	to		
any	OEM’s	
turbines!
#WindWebinar
Hard	Stop	in	a	1.65	MW	turbine	
	
Ini:al	Slip	Event	
Removes	Torsional	Energy	
1	
75-100%	Reduc:on	
Reverse	L...
#WindWebinar
	
Torsional	Oscilla&ons	and	Vibra&on	
*	Shockloads	Through	the	Turbine	*	
2	
Torque	Reversal	&	Impact	Loading...
#WindWebinar
	
During	Torque	Reversals,	load	zones	shiW	180⁰.
#WindWebinar
	
Calcula:ons	show	25+	year	life.	
	
	
Why	are	
bearings	
failing	
sooner?	
90%	Crack	Genera&on	
10%	Crack	Pr...
#WindWebinar
MORE	than	the	Gearbox:	
What	else	is	affected	by	transient	events?	
•  Main	Bearings	
•  Generator	Bearings	
•...
#WindWebinar
Recent	comple:on	of	the	first,		
independent,	non-OEM		
Failure	Modes	and	Effects	Analysis	
(FMEA)		
of	the	en:...
#WindWebinar
	
Sco^	Eatherton,	President,	Wind	Driven	LLC.	
Emil	Moroz,	President,	EM	Energy	LLC	
Dave	Heidenreich,	P.E.,	...
#WindWebinar
#WindWebinar
#WindWebinar
High Speed Shaft
Assembly
High Speed
Intermediate
Shaft
Assembly
Low Speed
Shaft
Assembly
Low Speed
Intermedi...
#WindWebinar
Internal	
Support	
(hrs)
Aver
Labor
($/h
Total	internal	cost
restore	compone
function
Projected	
Mean	Time	
B...
#WindWebinar
#WindWebinar
#WindWebinar
#WindWebinar
•  Actual	Costs	
•  Actual	Repairs	
•  Actual	KW-hr	
•  Actual	Capacity	
Factors
#WindWebinar
Internal	
Support	
(Man	hrs)
Average	
Labor	Cost	
($/hr)
Projected	
Mean	Time	
Between	
Failures/	
Repairs
(y...
#WindWebinar
Over	$11,000	annual	value	of	the	reduc:on	in	loads	to	
Gearbox	Components	alone,	not	coun:ng	lost	produc:on	
...
#WindWebinar
Annualized	“hard”	value:	
Over	$12,600	per	
year	installed	
	
With	lost	opportunity	
“soW	costs”,	such	as	los...
#WindWebinar
Current	Annual	Revenue/Turbine	
If	we	can	just	increase	availability	1%...	
	
Addi:onal	Revenue	=	$3,700/turb...
#WindWebinar
Down:me	is	more	expensive		
than	most	people	think!	
	
Down:me	costs	you	$1,000	a	day/turbine/
average	
Down:...
#WindWebinar
•  Transient	loading	is	going	on	in	your	turbines,	
likely	more	oWen	than	expected	
•  These	loads/events	can...
#WindWebinar
•  There	is	a	solu:on	that	addresses	many	of	the	
effects	of	these	loads	by	reducing	the	energy	
stored	in	the...
#WindWebinar
1.  Review	White	Paper	&	FMEA	–	this	will	be	
sent	to	all	webinar	aHendees.	
2.  Contact	AeroTorque	for	your	...
#WindWebinar
Michelle Froese
Senior Editor - Moderator
Windpower Engineering
& Development
mfroese@wtwhmedia.com
@Windpowe...
#WindWebinar
Thank You
q  This webinar will be available at
www.windpowerengineering.com & email
q  Tweet with hashtag #Wi...
Proactive Turbine Damage Reduction
Upcoming SlideShare
Loading in …5
×

Proactive Turbine Damage Reduction

687 views

Published on

Quantifying the value of reducing Transient Loads, utilizing a cost-based FMEA approach

Published in: Engineering
  • Be the first to comment

Proactive Turbine Damage Reduction

  1. 1. Proac&ve Turbine Damage Reduc&on -Quan&fying the value of reducing Transient Loads, u&lizing a life cost-based FMEA approach Webinar Series
  2. 2. #WindWebinar q  This webinar will be available afterwards at www.windpowerengineering.com & email q  Q&A at the end of the presentation q  Hashtag for this webinar: #WindWebinar Before We Start
  3. 3. #WindWebinar Michelle Froese Senior Editor - Moderator Windpower Engineering & Development Dustin Sadler Principal Engineer AeroTorque Corp. Doug Herr VP of Sales and Marketing AeroTorque Corp. Proactive Turbine Damage Reduction Meet your Presenters…
  4. 4. #WindWebinar 1.  What is a Transient Torsional Event? 2.  How do you mi:gate damaging TTEs? 3.  How does this affect turbine reliability? 4.  What is the value to your Cost of Energy?
  5. 5. #WindWebinar •  The data shows a 50-70% reduc:on in the worst loads from transient torsional events •  The value of those reduc:ons to your turbines and your boHom line!
  6. 6. #WindWebinar Taming Torsional Loads in the World’s Most Extreme Machines for 37 Years.
  7. 7. #WindWebinar This is your turbine making money!
  8. 8. #WindWebinar Example: Braking Procedure during a Hard Stop Normal Opera&on Stopping Protocol Triggered Combined Aero- and Caliper Disc Braking Torque Reversal when ShaM Stops The final torque reversal occurs when the shaW stops rota:ng!
  9. 9. #WindWebinar Any control system reac:on requiring rapid pitching and/or strong mechanical braking.
  10. 10. #WindWebinar •  E-stops are not the only hard stops. •  E-stops are not the only damaging type of stopping events.
  11. 11. #WindWebinar Winds also ini:ate transient loads!
  12. 12. #WindWebinar
  13. 13. #WindWebinar “Reverse Torsional Damper”
  14. 14. #WindWebinar 1.6 MW Turbine Ini:al Slip Event Removes Torsional Energy 1 50-75% Reduc:on Torsional Oscilla&ons 2 75-100% Reduc:on Reverse Loading 3
  15. 15. #WindWebinar These loads are not unique to any OEM’s turbines!
  16. 16. #WindWebinar Hard Stop in a 1.65 MW turbine Ini:al Slip Event Removes Torsional Energy 1 75-100% Reduc:on Reverse Loading 3 50-75% Reduc:on Torsional Oscilla&ons 2 1.65 MW Turbine
  17. 17. #WindWebinar Torsional Oscilla&ons and Vibra&on * Shockloads Through the Turbine * 2 Torque Reversal & Impact Loading * Torsional Loading w/o Rota:on * 3 Slipping begins * Limits Max Torque* 1 1.6 MW Turbine
  18. 18. #WindWebinar During Torque Reversals, load zones shiW 180⁰.
  19. 19. #WindWebinar Calcula:ons show 25+ year life. Why are bearings failing sooner? 90% Crack Genera&on 10% Crack Propaga&on Crack Genera&on Crack Propaga&on Failure
  20. 20. #WindWebinar MORE than the Gearbox: What else is affected by transient events? •  Main Bearings •  Generator Bearings •  Generator Rotor Windings •  High Speed Coupling •  Main ShaM to Hub Bolts •  Rotor Blades •  Blade to Pitch Bearing Bolts •  Electronics/ Electrical Systems •  Bedplate
  21. 21. #WindWebinar Recent comple:on of the first, independent, non-OEM Failure Modes and Effects Analysis (FMEA) of the en:re Turbine. White paper and FMEA available.
  22. 22. #WindWebinar Sco^ Eatherton, President, Wind Driven LLC. Emil Moroz, President, EM Energy LLC Dave Heidenreich, P.E., Founder and Re&red Chief Engineer of PT Tech, Inc. Dus&n Sadler, Principal Engineer, AeroTorque Corpora&on
  23. 23. #WindWebinar
  24. 24. #WindWebinar
  25. 25. #WindWebinar High Speed Shaft Assembly High Speed Intermediate Shaft Assembly Low Speed Shaft Assembly Low Speed Intermediate Shaft Assembly Images courtesy of Olympus-IMS and NREL
  26. 26. #WindWebinar Internal Support (hrs) Aver Labor ($/h Total internal cost restore compone function Projected Mean Time Between Failures/ Repairs (yrs) Component Expected Useful Turbine Life (yrs) Total external cost to restore component function
  27. 27. #WindWebinar
  28. 28. #WindWebinar
  29. 29. #WindWebinar
  30. 30. #WindWebinar •  Actual Costs •  Actual Repairs •  Actual KW-hr •  Actual Capacity Factors
  31. 31. #WindWebinar Internal Support (Man hrs) Average Labor Cost ($/hr) Projected Mean Time Between Failures/ Repairs (yrs) Mean Crane Cost ($/event) Estimated Downtime (days/event) Estimated Cost of Downtime ($/event) Calculated Annualized Value for Repairs or Replacements Component Expected Useful Turbine Life (yrs) Total external cost to restore component function Total internal cost to restore component function Projected Failures in Life of Turbine (yrs) Credibility of Evidence that links TTEs to failure mode Contribution Towards Failure (percentage) Estimated Life Extension (percentage) Estimated New Time Between Failures (yrs) Failure Modes that can be mitigated by a reduction in Transient Torque Events (TTEs) Projected Life Improvement for a WindTC in Mitigating TTE DamageProjected Annualized Value attributed to the WindTC Assuming No Downtime (no soft costs)
  32. 32. #WindWebinar Over $11,000 annual value of the reduc:on in loads to Gearbox Components alone, not coun:ng lost produc:on Gearbox High Speed Shaft Assembly (HSS) 20 5 $5,264 Bearing Fatigue - Surface & Subsurface - Macropitting $3,458.89 $2,102.52 Gearbox High Speed Intermediate Shaft Assembly (HSIS) 25 10 $6,095 Bearing Fatigue - Surface & Subsurface - Micropitting $3,054.85 $2,232.03 Gearbox Low Speed Intermediate Shaft Assembly (LSIS) 25 15 $11,770 Bearing Fatigue - Surface & Subsurface - Micropitting $2,391.93 $2,139.11 Gearbox Low Speed Shaft Assembly (LSS) 25 25 $10,062 Bearing Fatigue - Surface & Subsurface - Micropitting $4,879.69 $4,633.98 $13,785 $11,108 Assuming No Downtime (no soft costs) GEARBOX COMPONENTS Component Expected Useful Turbine Life (yrs) Projected Mean Time Between Failures/ Repairs (yrs) Calculated Annualized Cost for Repairs or Replacements Failure Modes that can be mitigated by a reduction in Transient Torque Events (TTEs) Projected Annualized Value attributed to the WindTC $13,785 $11,108
  33. 33. #WindWebinar Annualized “hard” value: Over $12,600 per year installed With lost opportunity “soW costs”, such as lost produc:on, the value grows to $15,000 Component Expected Useful Turbine Life (yrs) Projected Mean Time Between Failures/ Repairs (yrs) Calculated Annualized Cost for Repairs or Replacements Projected Annualized Value aHributed to the WindTC Projected Annualized Value without Down:me GEARBOX COMPONENTS Gearbox High Speed ShaW Assembly (HSS) 20 5 $5,264 $3,458.89 $2,102.52 Gearbox High Speed Intermediate ShaW Assembly (HSIS) 20 10 $5,748 $3,054.85 $2,232.03 Gearbox Low Speed Intermediate ShaW Assembly (LSIS) 20 10 $5,748 $2,391.93 $2,139.11 Gearbox Low Speed ShaW Assembly (LSS) 20 15 $9,766 $4,879.69 $4,633.98 TOTAL ANNUAL VALUE TO GEARBOX $13,785 $11,108 OTHER DRIVETRAIN COMPONENTS Main ShaW Bearings 20 15 $15,272 $1,189.24 $1,108.86 Generator Bearings 20 8 $1,626 $28.99 $24.06 Generator Rotor Windings 20 10 $14,628 $91.63 $81.93 High Speed Coupling 20 15 $841 $282.66 $233.09 Rotor Blade Repair 20 8 $3,111 $35.10 $29.90 Main ShaW to Hub Bolts 20 20 $8,651 $15.56 $15.36 Blade to Pitch Bearings and Bolts 20 20 $5,068 $16.68 $15.83 TOTAL ANNUAL VALUE TO OTHER DRIVETRAIN COMPONENTS $1,660 $1,509 OTHER TURBINE COMPONENTS Tower Repairs / Tower Bolts / Anchor Bolts 20 20 $1,484 $0.15 $0.13 Electronics / Electrical Systems 20 2 $2,306 $3.45 $1.80 Power Cables 20 20 $2,838 $0.00 $0.00 Bedplate 20 25 $7,818 $14.06 $12.57 TOTAL ANNUAL VALUE TO OTHER TURBINE COMPONENTS $18 $15 TOTAL ANNUAL VALUE TO ENTIRE TURBINE $15,462.88 $12,631.17
  34. 34. #WindWebinar Current Annual Revenue/Turbine If we can just increase availability 1%... Addi:onal Revenue = $3,700/turbine/year $0.08 (Rate) X 32% (Capacity) X 97% (Availability) X 365 days X 24 hrs X 1.65 MW = $359K
  35. 35. #WindWebinar Down:me is more expensive than most people think! Down:me costs you $1,000 a day/turbine/ average Down:me during produc:on Costs you $3,000/day!
  36. 36. #WindWebinar •  Transient loading is going on in your turbines, likely more oWen than expected •  These loads/events can cause long-term damage to your turbines
  37. 37. #WindWebinar •  There is a solu:on that addresses many of the effects of these loads by reducing the energy stored in the system •  This solu:on shows a return on investment of over $15,000/year, giving a pay back of less than a year
  38. 38. #WindWebinar 1.  Review White Paper & FMEA – this will be sent to all webinar aHendees. 2.  Contact AeroTorque for your customized ROI for your fleet and failure modes. 3.  Set up a mee:ng – Your site or ours.
  39. 39. #WindWebinar Michelle Froese Senior Editor - Moderator Windpower Engineering & Development mfroese@wtwhmedia.com @Windpower_Eng Dustin Sadler Principal Engineer AeroTorque Corp. dsadler@aerotorque.com @AeroTorque Doug Herr VP of Sales and Marketing AeroTorque Corp. dherr@aerotorque.com @AeroTorque Proactive Turbine Damage Reduction Questions?
  40. 40. #WindWebinar Thank You q  This webinar will be available at www.windpowerengineering.com & email q  Tweet with hashtag #WindWebinar q  Connect with Windpower Engineering & Development q  Discuss this on EngineeringExchange.com

×