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PHM Application for Utility-scale Wind Turbines

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Performance Health Monitoring application for utility-scale wind turbines presentation at IEEE conference by Brogan Morton.

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PHM Application for Utility-scale Wind Turbines

  1. 1. PHM Application for Utility-scale Wind Turbines Brogan Morton, NRG Systems
  2. 2. Presentation Overview• Why Health Monitoring for Wind Turbines?• Operational Cost Drivers• CBM/PHM Challenges – System Considerations – Operating Conditions – Diagnosis / Knowledge Creation
  3. 3. Why Health Monitoring?• Not driven by safety or operational effectiveness• It’s about the bottom line – Cost Avoidance • Maintenance Cost Optimization – $150k gearbox + $100k crane call – $30k-$50k uptower replacement • Prevent failures by finding failure drivers – misalignment, imbalance, etc.
  4. 4. Why Prognostics?
  5. 5. Operational Cost Drivers 35% to 45% of OPEX
  6. 6. Maintenance Drivers Drivetrain causes 50% of downtime
  7. 7. Typical Drivetrain Layout Doubly-Fed Induction Generator 3 Stage Gearbox - (900-1600 RPM) 1 planetary / 2 helical (80:1 - 100:1 ratio)Hub & Rotor(12-20 RPM)
  8. 8. Typical Drivetrain Layout Generator High Speed Shaft 3-stage Gearbox MainBearing Int. Speed Shaft Main Shaft Low Speed Shaft •17 Bearings •9 Gears •8 Shaft
  9. 9. Systems Considerations• Distributed power source – Goshen North ~ 124.5MW using 83 1.5MW turbines – 11,000 acres, 28 miles of access roads
  10. 10. Systems Considerations• Turbines are difficult to access – Climb an 80m (262 ft) tower then hoist tools – Hand-held CMS incurs a large labor cost
  11. 11. System Considerations• IT Infrastructure – Down-tower connection – Local network infrastructure – NERC Critical Infrastructure Protection (CIP) – Operation network security (AIC vs CIA)
  12. 12. Operating Conditions• Large variations in Main Rotor Speed speed – DFIG – Tower Shadow – Wind Shear Profile• Large variations in torque/power – 10% - 105% of rated
  13. 13. Knowledge CreationManually translating data into a diagnosis for every turbine has a large cost!Which is most useful to an operator?• 01000011 01101000 01100001 01101110 01100111 01100101 00100000 01101101 01100001 01101001 01101110 00100000 01100010 01100101 01100001 01110010 01101001 01101110 01100111• 43 68 61 6e 67 65 20 6d 61 69 6e 20 62 65 61 72 69 6e 67 0d 0a• Change main bearing

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