machinery prognostics and condition monitoring technical group › workshops › 2011 ›...

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Machinery Prognostics and Condition Monitoring Technical

GroupDr. Karl Reichard

Machinery Prognostics & Condition Monitoring Technical Group

Applied Research LaboratoryPhone: (814) 863-7681 Email: kmr5@psu.edu

Steve ConlonJeff BanksJason HinesJoe Rose

Cliff LissendonMarty TretheweyMitch LeboldJason Hines

Steve HambricJoe CusumanoJeff MayerBernie Tittman

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Wind Turbine Health Monitoring

Karl Reichard1, Eli Hughes1, Mark Turner1, Brenton Forshey2

1Applied Research Lab2Department of Aerospace Engineering

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Goals and Objectives

• Monitor health and status of individual wind turbines

• Facilitate CBM by predicting equipment failures and maintenance requirements

• Characterize wind-induced unsteady loads• Monitor health of generator, blades,

batteries, and power conversion and control electronics

• Optimize capacity of wind farm by aligning CBM with forecasted weather conditions

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Experimental Wind Turbine

• Instrumented Penn State Center for Sustainability’s Southwest Windpower Whisper 500, 3 kW, turbine

• Sensors:– 3 phase AC voltage and current– Converted DC power– Tower vibration– Local Meteorology– Blade vibration (planned)

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Wind Turbine Instrumentation

Wind

Blades Generator

Slip Ring

Tower

Electronics

Batteries

Met. Sensors

3-axis blade accel.

3-axis tower accel.

3-phase (AC) V&I3-axis gen vibe

Battery (DC) V&I

3-axis blade accel.

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Blade Health Monitoring

• Student team designed and is fabricating new blades for wind turbine

• New blades will contain embedded accelerometers to monitor blade vibration and unsteady loads

• Wireless monitoring system in hub will transmit vibration information to monitoring station at base of turbine.

• Future project – energy harvesting for wireless monitoring system

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• Triaxial accelerometer was installed 8 inches from the blade tip

• Cable will run to the hub where we will connect to a wireless transmitter

Accelerometer Installation

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System Design

Blades ElectricalGenerator Gearbox

Sensors

IntelligentSensorNode

IntelligentSensorNode

IntelligentSensorNode

IntelligentSensorNode

IntelligentSensorNode

IntelligentSensorNode

Sensors

SubsystemHealth

SubsystemHealth

SystemHealth

Operations

SubsystemHealth

Planning /Logistics

Knowledge

Data

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Wind Turbine Laboratory Testbed Suite

Blades Motor/ Generator Gearbox Electronics

Static & Dynamic Testing

Gear, Bearing and Shaft Testing

Generator electrical and mechanical

Power conversion and

switching

Energy Storage

Batteries

Monitoring System

Embedded Systems,

Processing, Data Fusion

Systems Integration

Lab

Enterprise Systems

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Wind Energy Enterprise Health Management

• Monitor health and status of individual wind turbines

• Facilitate CBM by predicting equipment failures and maintenance requirements

• Optimize capacity of wind farm by aligning CBM with forecasted weather conditions

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Jeff Banks, Mark Brought, Jason Estep, Jason Hines, Nathaniel Hobbs

Embedded Diagnostic and Predictive Technology Development for Platform

Power Generating Devices

Machinery Prognostics & Condition Monitoring Technical Group

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Objectives

• Demonstrate condition monitoring technologies on representative US Army tactical wheeled vehicle

• Vehicle Under Test: Freightliner 915 Truck

• Condition monitoring applied to detect alternator electrical (windings) and mechanical (bearing) faults

Machinery Prognostics & Condition Monitoring Technical Group

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Alternator

Machinery Prognostics & Condition Monitoring Technical Group

Stator

Rotor Assembly Rectifier Diodes in Housing

RegulatorHousing

Fan Blades

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Alternator Faults

Machinery Prognostics & Condition Monitoring Technical Group

Stator

Rotor Assembly Rectifier Diodes in Housing

RegulatorHousing

Fan Blades

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Alternator Instrumentation

Machinery Prognostics & Condition Monitoring Technical Group

CurrentSensor

Accelerometer

TemperatureSensor

MeasurementDescription

Sensor Model

Alternator Voltage LEM Model LV 20-PAlternator PhaseAB Voltage

LEM Model LV 20-P

Alternator PhaseBC Voltage

LEM Model LV 20-P

Alternator PhaseCA Voltage

LEM Model LV 20-P

Alternator FieldVoltage

LEM Model LV 20-P

Alternator Current LEM Model HAL200-S

Alternator FieldCurrent

LEM Model HAL 50-S

AlternatorTemperature

Standard K typeThermocouple

AlternatorVibration

PCB PiezotronicsModel 356M154

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Alternator Output Current

Machinery Prognostics & Condition Monitoring Technical Group

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

x 10-3

-0.5

-0.4

-0.3

-0.2

-0.1

0

0.1

0.2

0.3

0.4

0.5

Time (Seconds)

Amps

Time Domain Alternator Current Signature - 75 Amps - 100Hz Shaft Speed

Stator ShortNo Fault

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Alternator Output Current

Machinery Prognostics & Condition Monitoring Technical Group

0 2 4 6 8 10 12 14 16 18 20-140

-120

-100

-80

-60

-40

-20

0Power Spectral Density of Alternator Output Current

Frequency (kHz)

Pow

er S

pect

rum

Mag

nitu

de (d

B)

0 2 4 6 8 10 12 14 16 18 20-140

-120

-100

-80

-60

-40

-20

0Power Spectral Density of Alternator Output Current

Frequency (kHz)

Pow

er S

pect

rum

Mag

nitu

de (d

B)

No Fault

Stator Short

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Alternator Stator Short Fault Condition Indicator

Machinery Prognostics & Condition Monitoring Technical Group

0 1000 2000 3000 4000 5000 6000-100

-90

-80

-70

-60

-50

-40

-30

-20

-10

0

Frequency (Hz)

Pow

er S

pect

rum

Mag

nitu

de (d

B)

Power Spectral Density of Alternator Current

100Hz Alternator Shaft Speed150 Amp Load

1600Hz

3200Hz 4800Hz

600Hz

600Hz

600Hz

Comb filter used for fault detection

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Alternator Stator Short Fault Condition Indicator

Machinery Prognostics & Condition Monitoring Technical Group

0 1000 2000 3000 4000 5000 6000-100

-90

-80

-70

-60

-50

-40

-30

-20

-10

0

Frequency (Hz)

Pow

er S

pect

rum

Mag

nitu

de (d

B)

Power Spectral Density of Alternator Current

100Hz Alternator Shaft Speed150 Amp Load

1600Hz

3200Hz 4800Hz

600Hz

600Hz

600Hz

Comb filter used for fault detection

40 50 60 70 80 90 100 110

0

2

4

6

8

10

12

Alternator Shaft Speed

Con

ditio

n In

dica

tor M

agni

tude

Alternator Condition Indicator Response to Stator Winding Short

Stator Short - 75 AmpsStator Short - 50 AmpsStator Short - 25 AmpsNo Fault - 75 AmpsNo Fault - 50 AmpsNo Fault - 25 Amps

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Alternator Vibration Spectrum

Machinery Prognostics & Condition Monitoring Technical Group

0 0.2 0.4 0.6 0.8 1 1.2-90

-80

-70

-60

-50

-40

-30

-20

-10

0

Frequency (kHz)

Pow

er S

pect

rum

Mag

nitu

de (d

B)

Periodogram Power Spectral Density Estimate of Acceleration (Vertical)

Inner Race DefectNo Fault

1x ShaftSideband

538Hz

1x ShaftSideband

338HzInner Race Defect Frequency: 438Hz

2x ShaftSideband

238Hz

2x ShaftSideband

638Hz

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Conclusions

• Tested a variety of different faults on 140 Ampere Prestolite vehicle alternators for the Freightliner 915 truck.

• Alternators were then run under various electrical load and engine speed conditions to assess the detectability of faults utilizing different sensors and data collection systems

• Electrical fault of a single-phase stator winding short, and the induced mechanical fault of a defect on the bearing inner race were easily detected.

Machinery Prognostics & Condition Monitoring Technical Group

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Conclusions• The condition indicator algorithm developed for the single-

phase stator winding short looked at the variance in the time waveform of the sampled alternator current output– Simple and effective at indicating the presence of a seeded single

phase stator winding short at varying engine speeds and varying electrical loads.

– Can be implemented on existing fielded data analysis hardware that is currently being used on other vehicle systems in theater.

• A more robust algorithm based on the frequency analysis of the amplitude of harmonic components of the alternator signal was also developed. – Requires more computing horsepower, but is more sensitive to

earlier detection– Capable of giving a fault indication prior to failure that would allow

for condition based maintenance.Machinery Prognostics & Condition Monitoring Technical Group

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Mitch Lebold, Marty Trethewey, Nathan Lasut, Jonathan Bednar

Torsional Vibration Monitoring for Nuclear Power Plant Reactor Cooling

Pump Shaft Crack Monitoring

Machinery Prognostics & Condition Monitoring Technical Group

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Overview

• Multi-year project sponsored by EPRI• Uses torsional instead of lateral vibration

to monitor for cracks in RCP shaft• Prototype system developed and tested on

ARL test bed and on scale reactor test bed

Machinery Prognostics & Condition Monitoring Technical Group

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Experimental Test Bed

Machinery Prognostics & Condition Monitoring Technical Group

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Sensor Installation

Machinery Prognostics & Condition Monitoring Technical Group

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Torsional Vibration Spectrum

Machinery Prognostics & Condition Monitoring Technical Group

0 50 100 150 200 250

10-6

10-5

10-4

Frequency (Hz)

Degr

ees pe

ak

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Change in Torsional Vibration Frequency

Machinery Prognostics & Condition Monitoring Technical Group