Date post: | 05-Dec-2014 |
Category: |
Technology |
Upload: | renewable-nrg-systems |
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PHM Application for Utility-scale Wind Turbines
Brogan Morton, NRG Systems
Presentation Overview
• Why Health Monitoring for Wind Turbines?• Operational Cost Drivers• CBM/PHM Challenges– System Considerations– Operating Conditions– Diagnosis / Knowledge Creation
Why Health Monitoring?• Not driven by safety or
operational effectiveness• It’s about the bottom line– Cost Avoidance• Maintenance Cost Optimization
– $150k gearbox + $100k crane call – $30k-$50k uptower replacement
• Prevent failures by finding failure drivers– misalignment, imbalance, etc.
Why Prognostics?
Operational Cost Drivers
35% to 45% of OPEX
Maintenance Drivers
Drivetrain causes 50% of downtime
Typical Drivetrain Layout
Hub & Rotor(12-20 RPM)
Doubly-Fed Induction Generator
(900-1600 RPM)3 Stage Gearbox -1 planetary / 2 helical
(80:1 - 100:1 ratio)
Main Shaft
MainBearing
3-stage Gearbox
Generator
• 17 Bearings• 9 Gears• 8 Shaft
Low Speed Shaft
Int. Speed Shaft
High Speed Shaft
Car
rier
Pla
te
Typical Drivetrain Layout
Systems Considerations• Distributed power source– Goshen North ~ 124.5MW using 83 1.5MW turbines– 11,000 acres, 28 miles of access roads
Systems Considerations• Turbines are difficult to access– Climb an 80m (262 ft) tower then hoist tools– Hand-held CMS incurs a large labor cost
System Considerations
• IT Infrastructure– Down-tower connection– Local network infrastructure– NERC Critical Infrastructure Protection (CIP)– Operation network security (AIC vs CIA)
Operating Conditions
• Large variations in speed– DFIG– Tower Shadow– Wind Shear Profile
• Large variations in torque/power– 10% - 105% of rated
Main Rotor Speed
Knowledge Creation
Manually translating data into a diagnosis for every turbine has a large cost!
Which is most useful to an operator?• 01000011 01101000 01100001 01101110 01100111
01100101 00100000 01101101 01100001 01101001 01101110 00100000 01100010 01100101 01100001 01110010 01101001 01101110 01100111
• 43 68 61 6e 67 65 20 6d 61 69 6e 20 62 65 61 72 69 6e 67 0d 0a
• Change main bearing