1/28/20081DETECTING AND PREDICTING MW DETECTING AND PREDICTING MW WIND TURBINE DRIVE TRAIN WIND TURBINE DRIVE TRAIN FAILURESFAILURESDavid ClarkDavid ClarkDirector, Director, TurningpointTurningpoint//CommtestCommtestAdopted forWind Power Management classhttp://www.icaen.uiowa.edu/~ie_155/by Andrew KusiakIntelligent Systems Laboratory2139 Seamans CenterThe University of Iowa Iowa City, Iowa 52242 – [email protected]: 319-335-5934 Fax: 319-335-5669http://www.icaen.uiowa.edu/~ankusiakCauses of vibration Causes of vibration MISALIGNMENTMISALIGNMENTIMBALANCEIMBALANCEMECHANICAL LOOSENESSMECHANICAL LOOSENESSRESONANCERESONANCEBEARINGSBEARINGS90%90% of machine vibration is attributed to these 5 issuesof machine vibration is attributed to these 5 issuesTHE ABOVE PROBLEMS MANIFEST THEMSELVES IN THE CONDITION THE ABOVE PROBLEMS MANIFEST THEMSELVES IN THE CONDITION OF THE ASSET OF THE ASSET TYPICAL SENSOR LOCATIONSTYPICAL SENSOR LOCATIONSBasically monitor what fails or what is expensive when it Basically monitor what fails or what is expensive when it failsfails1/28/200823 COMMON 3 COMMON EXAMPLES OF MW EXAMPLES OF MW WTG ISSUESWTG ISSUES1. MISALIGNMENT1. MISALIGNMENT2. BEARINGS2. BEARINGS3. PLANETARY GEARBOX3. PLANETARY GEARBOXEXAMPLE # 1EXAMPLE # 1 Misalignment of a Megawatt class wind Misalignment of a Megawatt class wind turbineturbineGearbox to generatorGearbox to generatorGearbox to generatorGearbox to generator Shows as a high peak at the running speedShows as a high peak at the running speed First vibration signature shows First vibration signature shows .5.5 amplitude in a amplitude in a velocity measurement (before)velocity measurement (before) Second shows Second shows .025.025 amplitude after alignment amplitude after alignment (after)(after)BEFORE .5 BEFORE .5 High amplitude at running speedAFTERAFTER .025.0251/28/20083EXAMPLE # 2EXAMPLE # 2 BEARING FAULT IN A MEGAWATT CLASS BEARING FAULT IN A MEGAWATT CLASS WIND TURBINEWIND TURBINE COMMON BEARING ABREVIATIONSCOMMON BEARING ABREVIATIONSBPFOBPFO(outer race defect)(outer race defect)BPFOBPFO(outer race defect)(outer race defect) BPFIBPFI (inner race defect)(inner race defect) FTFFTF (cage defect)(cage defect) BSFBSF (rolling element defect)(rolling element defect) There are There are 2 2 ISO standards for alarms and 1 widely ISO standards for alarms and 1 widely accepted 30 year study also used for alarmingaccepted 30 year study also used for alarmingAMPLITUDE = SEVERITYAMPLITUDE = SEVERITYPROGRESSION OF THE PROGRESSION OF THE FAILUREFAILURE TYPES OF VIBRATION MEASUREMENTS INDICATE THE FAILURE TYPES OF VIBRATION MEASUREMENTS INDICATE THE FAILURE PROGRESSION OF THE COMPONENT. PROGRESSION OF THE COMPONENT. ““VELOCITYVELOCITY””AND AND ““DEMODULATEDDEMODULATED””MEASUREMENTS GIVE AN APPROXIMATE TIMELINEMEASUREMENTS GIVE AN APPROXIMATE TIMELINEHow do I interpret the results? Look for peaks at known bearing fault frequencies in both the normal vibration velocity spectra and the demodulated spectra.No peaks in either spectrum: Condition is good, use as a baseline for future comparisons. Peaks appear in Demod only: Early warning indication that defects exist (or the bearing needs lubrication). Peaks appear in Velocity and Demod spectra: Plan replacement at next maintenance period. Peaks appear in Velocity spectra only, combined with a rise in the Demod noise floor: Replace the bearing now!1/28/20084WIND TURBINES ARE VERY EASY TO WIND TURBINES ARE VERY EASY TO COMPARE TO EACH OTHER TO COMPARE TO EACH OTHER TO DETERMINE A FAULTDETERMINE A FAULTAlarm Types - Envelopes - Vertical - Vel Freq 12000 CPM0120.140.16O/All 0.251 in/s 0-pkorders0 1 2 3 4 5in/s 0-pk00.020.040.060.080.10.129/10/1998 7:25:20 AM O/All 0.251 in/s 0-pk 2381.2 RPMVIBRATION ANALYSIS INTERPRETATION IS VIBRATION ANALYSIS INTERPRETATION IS REDUCED TO REDUCED TO TRAFFIC SIGNALSTRAFFIC SIGNALSWITH ALL WITH ALL MAJOR CONDITION MONITORING MAJOR CONDITION MONITORING SUPPLIERSSUPPLIERSGOOD(.03) vs. BAD(.3)GOOD(.03) vs. BAD(.3)Generator BearingGenerator BearingGenerator - GNDE - Horizontal [Tach] - Acc Freq 2000 Hz [Tach]8/30/2007 8:10:57 AM0.20.250.3O/All 0. 376 g rmsGenerator - GNDE - Horizontal [Tach] - Vel Freq 2000 Hz [Tach]8/30/2007 8:11:03 AM0.020.0250.03134.943 deg0 in/s210.351 Hz12.639 ordersCursor A :O/All 0.037 in/s 0-pkorders0 20 40 60 80 100 120g rms00.050.10.158/30/2007 8:10:57 AMO/All 0. 376 g rms998.615 RPMNU224E.TUP2 FTFINU224E.TUP2 FTFINU224E.TUP2 FTFINU224E.TUP2 FTFINU224E.TUP2 FTFINU224E.TUP2 FTFIorders20 40 60 80 100 120in/s 0-pk00.0050.010.0158/30/2007 8:11:03 AMO/All 0.037 in/s 0-pk998.544 RPMNU224E.TUP2 BSFNU224E.TUP2 BS FNU224E.TUP2 BS FNU224E.TUP2 BSFNU224E.TUP2 BS FNU224E.TUP2 BSFThere are There are 2 2 ISO standards for alarms and 1 widely accepted 30 year study also used for alarmingISO standards for alarms and 1 widely accepted 30 year study also used for alarmingMEGAWATT GENERATOR MEGAWATT GENERATOR BEARINGBEARINGlooks like this:looks like this:1/28/20085VIBRATION SIGNATURE IS LABELED WITH VIBRATION SIGNATURE IS LABELED WITH BPFI BPFI (INNER RACE DEFECT)(INNER RACE DEFECT)P426551-154 load - down wind bracke - Horizontal - Demod (2-10kHz) 120000 CPM [Tach]12/14/2007 1:33:47 PM0.0120.0140.013 g17.972 orders20362.5 CPMCursor A:O/All 0.071 g rmsMachine Note (12/14/2007 8:18:19 AM)The generator run at full speed and full load.the test was done with the test rectifer.Please consider no fan on the last two tests.CPM0 20,000 40,000 60,000 80,000 100,000 120,0g rms00.0020.0040.0060.0080.0112/14/2007 1:33:47 PM O/All 0.071 g rms 1133 RPMNU224E.TUP2 BPFI (+/- 1X)NU224E.TUP2 BPFI (+/- 1X)NU224E.TUP2 BPFI (+/- 1X)NU224E.TUP2 BPFI (+/- 1X)NU224E.TUP2 BPFI (+/- 1X)NU224E.TUP2 BPFI (+/- 1X)MEGAWATT CLASS GENERATOR MEGAWATT CLASS GENERATOR BEARINGBEARINGlooks like this:looks like this:GEARBOX PLANET BEARINGGEARBOX PLANET BEARINGlooks like this:looks like this:1/28/20086Gearbox - Planet - Vertical - Demod (2-10kHz) 1000 Hz12/22/2005 3:01:51 AMpk0.0040.0050.0060.0070.006 in/s24.793 orders30 HzCursor A:O/All 0.322 in/s 0-pk6017 BPFI -2.1%6017 BPFI -2.1%BPFI -2.1%Hz20 30 40 50 60 70 80 90 100in/s 0--0.00100.0010.0020.00312/22/2005 3:01:51 AM O/All 0.322 in/s 0-pk 72.6 RPM6017 BPFI -2.1%6017 BPFI -2.1%6017 BEXAMPLE # 3EXAMPLE # 3 MW WIND TURBINE GEARBOX GEAR MW WIND TURBINE GEARBOX GEAR ISSUEISSUE There