emerging diagnostic technologies
DESCRIPTION
This presentation was made at the Wind Energy Update O&M conference in Dallas, TX on April 9, 2013. This presentation included an interactive survey of attendees, the results of which have also been uploaded ot SlideShare.TRANSCRIPT
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Emerging Technologies for Drivetrain Condition Monitoring
Rich Wurzbach, MRG Labs
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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
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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
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Poll: Are you currently performing Condition M...
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Poll: Do you utilize any condition monitoring ...
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Poll: Do you believe your current level of app...
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Poll: Which technology that you are currently ...
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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.
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Infrared Thermography
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Infrared of generator connections
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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
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Ultrasonic Monitoring
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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
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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
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Wind Turbine Sampling
Photo by Steffen Bots, Oelcheck
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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
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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
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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
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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.
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Acoustic Emission
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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.
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Poll: If you utilize a third-party maintenance...
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Poll: As a result of this presentation, are yo...