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Bachmann electronic GmbH
CONDITION MONITORING OF THE
DRIVE TRAIN MYTHS
end of warranty and permanent installations
- David...
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 TECHNIQUES
Component detection percentages on a typical gearb...
Bachmann electronic GmbH
DIFFERENT TYPES OF VIBRATION UNITS- Velocity, acceleration,
displacement, demodulated/enveloped, ...
Bachmann electronic GmbH
CONDITION MONITORING MYTHS
. Need lots of data, lots of measurements, with a baseline
. Too diffi...
Bachmann electronic GmbH
FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz
30/04/2004 2:14:30 p.m.
Hz
0 200 400 600 800 ...
Bachmann electronic GmbH
FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz
7/07/2004 5:04:47 p.m.
Hz
0 200 400 600 800 1...
Bachmann electronic GmbH
HIGH SPEED SECTION (HSS)
Bachmann electronic GmbH
HIGH SPEED SECTION (HSS)
secs
0 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 0.0...
Bachmann electronic GmbH
PLANETARY SECTION
secs
0 10 20 30 40 50 60
g
-1
0
1
2
3
4
O/All 0.312 g RMS
Machine Note (3/8/201...
Bachmann electronic GmbH
CONDITION MONITORING MYTHS
. Need lots of data, lots of measurements,
with a baseline
. Too diffi...
Bachmann electronic GmbHWind FACTS V2.2
CPM
0 20,000 40,000 60,000 80,000 100,000 120,000
gRMS
0
0.02
0.04
0.06
0.08
0.1
0...
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 diffi...
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 diffi...
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 S...
Bachmann electronic GmbH
CONDITION MONITORING MYTHS
. Need lots of data, lots of measurements,
with a baseline
. Too diffi...
Bachmann electronic GmbH
TRENDING EXAMPLES
Bachmann electronic GmbH
6/11
warning
8/26
Replacement
of the gearbox
1/8
alarm
planetary stage
Bachmann electronic GmbH
2/3
warning
5/13
Replacement
of the bearing
2/17
alarm
HSS bearing
Bachmann electronic GmbH
DAVID CLARK
d.clark@bachmann.info
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David Clark: 2013 Sandia National Laboratoies Wind Plant Reliability Workshop

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Condition Monitoring of the Drive Train Myths

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David Clark: 2013 Sandia National Laboratoies Wind Plant Reliability Workshop

  1. 1. Bachmann electronic GmbH CONDITION MONITORING OF THE DRIVE TRAIN MYTHS end of warranty and permanent installations - David Clark
  2. 2. Bachmann electronic GmbH WHAT WILL FAIL? AVERAGE SIZE 1.5-2.5MW
  3. 3. Bachmann electronic GmbH WHAT WILL FAIL AT EACH SENSOR LOCATION?
  4. 4. Bachmann electronic GmbH  TURBINE GEARBOX COMMON INSPECTION TECHNIQUES Component 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
  5. 5. Bachmann electronic GmbH DIFFERENT TYPES OF VIBRATION UNITS- Velocity, acceleration, displacement, demodulated/enveloped, time waveform, overall. TIME WAVEFORM VIBRATION SPECTRUM FFT
  6. 6. 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
  7. 7. Bachmann electronic GmbH FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz 30/04/2004 2:14:30 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/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 Hz 7/07/2004 5:04:47 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/All 0.468 g rms 7/07/2004 5:04:47 p.m. O/All 0.468 g rms <set RPM> RING GEAR
  8. 8. Bachmann electronic GmbH FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz 7/07/2004 5:04:47 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/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 Hz 30/04/2004 2:14:30 p.m. Hz 0 200 400 600 800 1,000 1,20 grms 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 O/All 0.991 g rms 30/04/2004 2:14:30 p.m. O/All 0.991 g rms <set RPM>
  9. 9. Bachmann electronic GmbH HIGH SPEED SECTION (HSS)
  10. 10. Bachmann electronic GmbH HIGH SPEED SECTION (HSS) secs 0 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 RPM T04 Gbx HighSpeed Horizontal [Tach] Acc Wfm 8000 ms 3/14/2011 3:18:04 PM O/All 0.23 g RMS 1829.291 RPM
  11. 11. Bachmann electronic GmbH PLANETARY SECTION secs 0 10 20 30 40 50 60 g -1 0 1 2 3 4 O/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 RPM T03 Gbx Planetary Horizontal [Tach] Acc Wfm 64000 ms 6/23/2011 8:10:43 AM O/All 0.035 g RMS 20.297 RPM
  12. 12. 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
  13. 13. Bachmann electronic GmbHWind FACTS V2.2 CPM 0 20,000 40,000 60,000 80,000 100,000 120,000 gRMS 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 RMS Turbine 19 high Speed Vertical Demod Spec (2-10kHz) 120000 CPM 8/17/2009 8:09:24 AM O/All 0.03 g RMS QJ328BPFI QJ328BPFI QJ328BPFI QJ328BPFI HIGH SPEED SHAFT (HSS) $300,000 spectrum
  14. 14. Bachmann electronic GmbH GENERATOR BEARING, $95k spectrum
  15. 15. Bachmann electronic GmbH EPRI REPORT COST JUSTIFICATIONS
  16. 16. 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
  17. 17. Bachmann electronic GmbH PLANET GEAR BEARING
  18. 18. Bachmann electronic GmbH PLANET GEAR
  19. 19. Bachmann electronic GmbH PLANET SECTION
  20. 20. Bachmann electronic GmbH PLANET GEAR
  21. 21. 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
  22. 22. Bachmann electronic GmbH +/- 20% ACCURACY
  23. 23. Bachmann electronic GmbH 60 RPM + 12 RPM +
  24. 24. Bachmann electronic GmbH +/- 20% ACCURACY BOTH ARE CURRENTLY BEING INSTALLED WITH OEM CONDITION MONITORING SYSTEMS WRONG SENSORS +/- 20% ACCURACY USING HIGH SPEED SENSOR IN LOW SPEED LOCATION
  25. 25. 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
  26. 26. Bachmann electronic GmbH TRENDING EXAMPLES
  27. 27. Bachmann electronic GmbH 6/11 warning 8/26 Replacement of the gearbox 1/8 alarm planetary stage
  28. 28. Bachmann electronic GmbH 2/3 warning 5/13 Replacement of the bearing 2/17 alarm HSS bearing
  29. 29. Bachmann electronic GmbH
  30. 30. DAVID CLARK d.clark@bachmann.info

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