Emerging Technologies for Wind Drivetrain Condition Monitoring
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A presentation from the Wind Energy Update O&M Conference in Dallas, TX in April 2013-UPDATE: Includes survey responses embedded
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Emerging Technologies for Wind Drivetrain Condition Monitoring
- 1. Emerging Technologies for Drivetrain Condition Monitoring Rich Wurzbach, MRG Labs
- 2. Emerging Technologies for Drivetrain Condition Monitoring • Wind turbines are provided with basic diagnostic systems and data delivery and archiving • Real-time monitoring has advantages in remote delivery and rapidly degrading (short P-F curve) failure modes • Proven technologies in other power generation applications can expand monitoring effectiveness for drivetrain components
- 3. Emerging Technologies: Proven in Power Generation • Infrared Thermography – electrical, mechanical and flow applications widespread in power plants • Grease Analysis—technology lags oil analysis, but new sampling and analysis techniques used in power gen, manufacturing applications • Acoustic Emission—early military applications, used in structural analysis, complement to vibration analyiss
- 4. How To Vote via Texting 1. Standard texting rates only (worst case US $0.20) 2. We have no access to your phone number 3. Capitalization doesn’t matter, but spaces and spelling do TIPS
- 5. Poll: Are you currently performing Condition M...
- 6. Poll: Do you utilize any condition monitoring ...
- 7. Poll: Do you believe your current level of app...
- 8. Poll: Which technology that you are currently ...
- 9. Retrofit and Periodic route- based condition monitoring • Handheld and sampling-based analysis can be performed at low cost-impact during uptower maintenance activities • Route-based analysis limited by turbine access frequencies • Supplemental vibration analysis, acoustic emission, oil analysis, grease analysis, infrared thermography, ultrasonic monitoring.
- 12. Infrared Thermography • Advantages – Infrared cameras are lower cost, lightweight and can be carried uptower on maintenance inspections – Electrical system problems can be detected early, limiting downtime and fire-risk • Disadvantages – Skill required to interpret images – Some targets might not be easily viewable
- 14. Ultrasonic Monitoring • Advantages – Can evaluate lubrication effectiveness, turbulent flow conditions (hydraulics), electrical arcing of breakers, connections, brushes – Lightweight and portable equipment – Detect multiple issues – Sounds are intuitive, short learning curve • Disadvantages – Typically requires further analysis to pinpoint problem
- 15. Grease sampling • Oil analysis is well-established and in widespread use • Relative ease in obtaining oil samples (existing or installed valves or fittings) based on oil’s ability to flow • Grease as a non-Newtonian fluid presents sampling challenges • Tools effective in sampling oil typically not effective for greases
- 16. Wind Turbine Sampling Photo by Steffen Bots, Oelcheck
- 17. Danish Wind Producers Main Bearing Grease Sampling Project • Key players DONG Energy and Vattenfall major offshore wind operators in Europe • Team assemble to evaluate sampling methods and value of grease analysis • 1-dimensional and 3-dimensional sampling performed on inservice and failed bearings • Project expanded to Horns Rev 1 project, other wind farms across Europe
- 18. Main Bearing Sampling • For bearings with drain plug/access port, sample can be positioned at face of bearing • 1 gram sample is obtained from this live zone
- 19. No drain, other samples • When direct access to grease is provided or required, spatula tool and syringe are used to compile sample • Target grease is from the active zone in the bearing or gears Photo: DONG Energy
- 20. Acoustic Emission • Tested at the USDA-ARS site in Bushland, TX • Testing both for drivetrain components and structural elements such as blades • Some bearing failure modes do not produce traditional vibration signatures until very late in failure • AE can be early detection system, can be partnered with grease analysis for fretting wear evaluation in main bearings.
- 22. If you utilize a third-party maintenance provider, how important is the offer or use of diagnostic technologies in selecting or maintaining them as your service provider? A. No difference-we select them based on maintenance competencies B. I would consider changing to a maintenance service provider that offers or provides advanced diagnostic technologies C. I would expand my current contract to include advanced diagnostic technologies D. I do not have budget to fund activities beyond basic maintenance services.
- 23. Poll: If you utilize a third-party maintenance...
- 24. Poll: As a result of this presentation, are yo...
Editor's Notes
- This slide is for display to the audience to show them how they will vote on your polls in your presentation. You can remove this slide if you like or if the audience is already comfortable with texting and/or voting with Poll Everywhere.Sample Oral Instructions:Ladies and gentlemen, throughout today’s meeting we’re going to engage in some audience polling to find out what you’re thinking, what you’re up to and what you know. Now I’m going to ask for your opinion. We’re going to use your phones to do some audience voting just like on American Idol.So please take out your cell phones, but remember to leave them on silent. You can participate by sending a text message.This is a just standard rate text message, so it may be free for you, or up to twenty cents on some carriers if you do not have a text messaging plan. The service we are using is serious about privacy. I cannot see your phone numbers, and you’ll never receive follow-up text messages outside this presentation. There’s only one thing worse than email spam – and that’s text message spam because you have to pay to receive it!
- Poll: Are you currently performing Condition M...\r\n\r\nPress F5 or enter presentation mode to view the poll\r\nIn an emergency during your presentation, if the poll isn't showing, navigate to this link in your web browser:\r\nhttp://www.polleverywhere.com/multiple_choice_polls/nviYexj7VkDwrJrIf you like, you can use this slide as a template for your own voting slides. You might use a slide like this if you feel your audience would benefit from the picture showing a text message on a phone.
- Poll: Do you utilize any condition monitoring ...\r\n\r\nPress F5 or enter presentation mode to view the poll\r\nIn an emergency during your presentation, if the poll isn't showing, navigate to this link in your web browser:\r\nhttp://www.polleverywhere.com/multiple_choice_polls/THBI4g0goosGe4OIf you like, you can use this slide as a template for your own voting slides. You might use a slide like this if you feel your audience would benefit from the picture showing a text message on a phone.
- Poll: Do you believe your current level of app...\r\n\r\nPress F5 or enter presentation mode to view the poll\r\nIn an emergency during your presentation, if the poll isn't showing, navigate to this link in your web browser:\r\nhttp://www.polleverywhere.com/multiple_choice_polls/JBFGZWkCKIDqmzGIf you like, you can use this slide as a template for your own voting slides. You might use a slide like this if you feel your audience would benefit from the picture showing a text message on a phone.
- Poll: Which technology that you are currently ...\r\n\r\nPress F5 or enter presentation mode to view the poll\r\nIn an emergency during your presentation, if the poll isn't showing, navigate to this link in your web browser:\r\nhttp://www.polleverywhere.com/multiple_choice_polls/rkjWa0IrhqRpEhQIf you like, you can use this slide as a template for your own voting slides. You might use a slide like this if you feel your audience would benefit from the picture showing a text message on a phone.
- Poll: If you utilize a third-party maintenance...\r\n\r\nPress F5 or enter presentation mode to view the poll\r\nIn an emergency during your presentation, if the poll isn't showing, navigate to this link in your web browser:\r\nhttp://www.polleverywhere.com/multiple_choice_polls/XZDCej1vwde013pIf you like, you can use this slide as a template for your own voting slides. You might use a slide like this if you feel your audience would benefit from the picture showing a text message on a phone.
- Poll: As a result of this presentation, are yo...\r\n\r\nPress F5 or enter presentation mode to view the poll\r\nIn an emergency during your presentation, if the poll isn't showing, navigate to this link in your web browser:\r\nhttp://www.polleverywhere.com/multiple_choice_polls/dBVutakYXXH7Or4If you like, you can use this slide as a template for your own voting slides. You might use a slide like this if you feel your audience would benefit from the picture showing a text message on a phone.