Comparing Replacement Components to Extend the Life of Gearboxes
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Making the right decisions on the sub-component gears and bearings in your gearbox bill of materials is critical to maximize life. However, operators, OEMs, and suppliers face uncertainty of the life extension benefits of one component versus another without heavy investment into hardware testing. This presentation will outline how Virtual Supplier Qualification can help determine the best cost/benefit between suppliers for gearbox component replacements by leveraging High Performance Computing, multi-physics prognostic models, and simulations and data analytics.
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Comparing Replacement Components to Extend the Life of Gearboxes
- 1. Comparing Replacement Components to Extend the Life of Gearboxes
- 2. Summary • What are the Pros and Cons of Uptower replacements and what challenges do they help solve in the wind industry? • How does prognostic data help operators set-up proactive uptower and downtower major component replacement strategies to maximize ROI? • Case Study: Broadwind DriveMAX Ring Gear Upgrade Comparison • Q/A Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 3. • 15+ years of drivetrain, blade and field service experience across numerous platforms • kW to MW inspection, test, repair & swap capabilities • In-house precision gearing shop Harness our expertise across WTG platforms to expand your business Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 4. Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015 Most Comprehensive Uptower Repair Offerings on the Market Two Shop Locations
- 5. Increase asset life Increase major component budget accuracy Minimize long term maintenance costs Eliminate gearbox CapEx Limit turbine down time Reduce crane costs Reduce shipping costs Less management resources consumed Importance of a Healthy Gearbox Proactive approach = reduces risk 5 Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 6. Uptower Shop Rebuild Assessment Safety Cost Time frame Cleanliness Testing Validation/Quality Control Uptower vs. Shop Gearbox Rebuild Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 7. Cleanliness Environmental concerns related to cleanliness Proper flush and break in Gear and bearing asperities from manufacturing Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 8. Testing Test stand 2-stage test uptower Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 9. Validation/Qualit y Control CM Wear Pattern Oil Analysis Quality Reporting Procedures Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 10. DigitalClone Live – Site Level Asset Ranking Default Most-at-Risk, Sortable, Filterable … Asset Map View Risk Level, Interactive, Navigable Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 11. Component Risk Failure risk ranking down to the component level for O&M planning (e.g. uptower vs crane) DigitalClone Live – Component Level Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 12. DigitalClone Live – Individual Component Tracking Individual Component Replacement Tracking Component failure risk predicted individually as part of the system per installation date Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 13. DigitalClone Live – ROI Optimization ROI Optimization All trade-offs based on ROI at the individual asset level/group, maximizing ROI for the fleet. Grouping Asset type, sub-site, region, etc. Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 14. Maximize the lifecycle of your drivetrains Inspections & failure mode analysis Data analysis Upgrade rebuilt gearboxes Uptower gearbox remanufacturing Oil changes, major component exchanges, and “turn-key” service 14 Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 15. 15 Gearbox Upgrades 15 • Gearing • Bearings • Lubrication Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 16. Gearbox Upgrades: Gearing • Geometry • Heat Treat • Material Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 17. Gear Box Upgrades: Bearings • Work closely with bearing OEMs on RCAs • Validate upgraded bearing solution through test and inspections. Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 18. Gearbox Upgrades: Lubrication • Work with OEMs to add lines, flush and clean • Heat exchangers and plumbing • Seal upgrades Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 19. Broadwind and Sentient Science Partnership • In-depth metallurgic analysis • Prognostics to validate the life extension benefit • In-depth understanding of failure modes based on inspections and RCA Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 20. Build DigitalClone Prognostic Model Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015 Ring Gear Ring Gear #1 Process: machine and cut teeth, contour induction harden teeth, finish machine and finish grind teeth. Ring Gear #2 Process: machine and cut teeth, carburize and harden, finish machine and finish grind teeth. DriveMAX Ring Gear #3 Process: machine and cut teeth, heat treat, grind teeth, contour induction harden, finish machine and finish grind teeth.
- 21. Ring Gear Fatigue Comparison Results Sentient Predictions L50 (Years of Operation) OEM Ring Gear Alt. Ring Gear DriveMax 4340 Ring Gear 4.72 14.93 37.84 - 3.2x 8x Fatigue Life Predictions – Load Case 1 – Max. Contact Stress: 1371.2MPa LEGEND Ring Gear #1 Ring Gear #2 DriveMax Ring Gear Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 22. New advanced steels for gearing applications: Commercially available Ferrium® C61™ and C64® Typical Alloy Properties YS (ksi) UTS (ksi) Core Hardness (HRC) El (%) RA % Fracture Toughness (ksiin) Achievable Surface Hardness (HRC) Tempering Temperature (°F) AISI 8620 121 168 41-48 14 53 53 450 18 Cr-Ni- Mo-7-6 150 200 30-40 13 71 60-63 300-350 Ferrium® C61 225 240 48-50 16 70 130 60-62 900 Ferrium® C64 199 229 48-50 18 75 85 62-64 925 Strength, toughness, and fatigue (axial and single tooth bending) performance upgrades versus existing gear steels 18 Cr-Ni-Mo-7-6 (standard wind turbine gear material) and AISI 8620 • Being qualified for helicopter transmission gears and rotor shafts; Increased power density • Used in NASCAR and F-1; Increased component life and durability C61 steel forward rotor shaft New materials should be considered to improve reliability of wind turbine gear boxes Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
- 23. Summary • Sentient allows customers to simulate the Gearbox RUL before and after component replacement • There are scenarios where Gearboxes will not have expected extended life – you want to know before replacement • Todays its possible to create a prioritized list of all GBXs where up- component replacement may be a clear lower cost alternative to gearbox replacement • The same method can be used to create a watch list for optimized borescoping schedules • You can validate the life of existing designs or new designs computationally • Check with Broadwind direct for uptower component options and services Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Editor's Notes
- How does DigitalClone Live help operators set-up an optimized Uptower and downtower replacement program? First, the model can help operators drive down cost to assess the condition of their gearboxes. Instead of borescoping every turbine, operators will choose to run borescopes or oil samples on only the critical turbines with failure risk of <1 year. Optimize your assessment programs. Once you have this data, you’re ready to set-up your O&M strategies.
- Prognostics model can help determine where to do Uptower replacements, and where to do full gearbox swaps. The DigitalClone model for each turbine lists the critical components and their life. If a high speed bearing is going to fail but the other gear life is fine, you can spend $20,000 and get a boost in RUL. If a planetary gearset is going to fail, and there is debris in the oil already, you should do a larger swap out of $400,000. Get the dramatic life extension benefits. Ultimately, you now have the data to decide how to do major component repairs, and how to plan your inventory spares, OPEX and CAPEX budgets for the year or years upfront. This can be done in house or under a service contract.
- When you’ve made decisions to do an Uptower repair (or a gearbox swap), how do you know which is the best supplier? The key is that you want to get the right amount of RUL extension, for the right price, at the right time. For example, if supplier A gives 18 months of life extension, and the failure will occur in the summer…that may be more beneficial to minimize downtime. Even if supplier B gets 24 months, but failure lands in the winter. You can run these optimization programs. You have the data to make informed decisions. And for suppiers, you can show your competitive advantage to be compensated for your value.
- Ultimately, the goal of any O&M program is to maximize the value of your assets. And maximize cash flows. With the trade-off simulations – you can evaluate multiple decisions to find the best ROI. Uptower replacements, uprating scenarios, load mitigation techniques or tools such as de-rating, oil flush. You can data to see how all of these effect the future life of your turbine. You have specific ROI calculators do these O&M decisions are tied to asset managers. You have control of your turbine life, and control to be proactive in your maintenance planning to drive down O&M costs. Now I’ll pass back to Jason – let’s show an example of an Uptower upgrade Broadwind put into place for GETS gearbox..and how they validated the life with DigitalClone prognostic models.
- Wes, I would walk through the slide along the lines of the following: The steel used in wind turbine gearboxes were designed several decades ago and may not be the best choice for optimum reliability There are new advanced gear steels being adopted in the aerospace industry for demanding helicopter transmission and rotor shaft applications for increased power density, and that are being used in NASCAR and F1 for increased component life Two new advanced steels that are commercially available are Ferrium C61 and C64 which offer greater strength, toughness, temperature resistance and fatigue performance versus existing wind turbine gear steels such as 18 Cr-Ni-Mo-7-6 Given the reliability issues of wind turbine gear boxes, it makes sense to consider new advanced materials such as Ferrium C61 and C64 POLL QUESTION 3#