improving wind turbine gearbox reliability n.
Download
Skip this Video
Loading SlideShow in 5 Seconds..
Improving Wind Turbine Gearbox Reliability PowerPoint Presentation
Download Presentation
Improving Wind Turbine Gearbox Reliability

Loading in 2 Seconds...

play fullscreen
1 / 17

Improving Wind Turbine Gearbox Reliability - PowerPoint PPT Presentation


  • 96 Views
  • Uploaded on

Improving Wind Turbine Gearbox Reliability. Walt Musial National Renewable Energy Laboratory Golden, Colorado USA walter_musial@nrel.gov Coauthors: Sandy Butterfield and Brian McNiff. Observations on the basic problems. Actual life is below expected design life.

loader
I am the owner, or an agent authorized to act on behalf of the owner, of the copyrighted work described.
capcha
Download Presentation

PowerPoint Slideshow about 'Improving Wind Turbine Gearbox Reliability' - curran-peters


An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -
Presentation Transcript
improving wind turbine gearbox reliability

Improving Wind Turbine Gearbox Reliability

Walt Musial

National Renewable Energy Laboratory

Golden, Colorado USA

walter_musial@nrel.gov

Coauthors: Sandy Butterfield and Brian McNiff

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

observations on the basic problems
Observations on the basic problems
  • Actual life is below expected design life.
  • Problems are generic in nature.
  • Poor quality is not the primary cause.
  • Most failures initiate in the bearings.
  • Problems are more dependent on bearing configuration than size.

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

bearing failure observations
Bearing Failure Observations
  • General adherence to design standards
  • ISO 281:2007
  • Proprietary codes prevent design transparency.
  • Bearing manufacturers are not equipped to solve the problem on their own.
  • No single, simple solution is expected.
  • Collaborative approach is needed.
  • Weaknesses in the design process are suspected.

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

possible design process weaknesses
Possible Design Process Weaknesses
  • Missing Load Cases
  • Irregular or unanticipated bearing responses
  • Excessive flexibility of gearbox mount.
  • Non-uniform safety applied to gearbox subcomponents.

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

typical wind turbine architecture
Typical Wind Turbine Architecture

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

typical gearbox mounting
Typical Gearbox Mounting

Hub

Main Low Speed Shaft Bearing

Gearbox

Trunnion Mounts

Mainshaft

Bedplate

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

trouble spots
Trouble Spots
  • Planet bearings
  • Intermediate shaft-locating bearings
  • High-speed locating bearings

3

2

1

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

test articles phase i
Test Articles (phase I)
  • Test platform between 600-kW and 900-kW.
  • 2 gearboxes with identical instrumentation.
  • Upgrade both units to state-of-the art.
    • Cooling, filtration, gear finish, lubrication, and bearing types.
  • Measure External and internal loads and displacements.
  • Thermal measurements
  • Condition monitoring
  • Expert failure analysis and forensics

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

three point approach
Three Point Approach

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

slide10

NREL Dynamometer Specifications

  • 2.5 MW power delivery
  • Full power regeneration at 480/575/690 or 4160 volts
  • Torque input range 0 - 1.62 million N-m.
  • Speed range from 0 - 2250 RPM
  • ~500 kN non-torque shaft loads capacity.
  • SCADA and automated torque/speed controls

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

dynamometer testing
Dynamometer Testing
  • Measure bearing responses to controlled load cases.
  • Increase load complexity and build confidence.
  • Develop non-torque load capability and simulate actual operating conditions.
  • Establish transfer functions between shaft loading and bearing responses.

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

field testing
Field Testing
  • Ponnequin Windfarm in Northern Colorado USA
  • Extensive measurements on a single turbine.
  • Characterize load events
  • Correlate loads with component internal gearbox responses.
  • Site-wide failures and statistics.

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

drivetrain analysis
Drivetrain Analysis
  • Multi-body dynamic analysis of test article.
  • Codes: FAST, Simpack, LVR
  • Model bearing response under various load conditions measured in Dyno and Field.
  • Model drivetrain solutions with tuned model.

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

summary
Summary
  • Bearing failures are contributing to fleet-wide reductions in wind turbine gearbox life.
  • A comprehensive three-part program to identify and fix weaknesses in the design process was initiated at NREL.
  • A collaborative long-term approach is required involving all stakeholders.

European Wind Energy Conference

Milan, Italy

May 7-11, 2007

slide16

Panel Questions 1

  • What is different with the Wind Turbine application compared to other industries
  • What efforts (technical) are happening with your part of the industry to improve reliability (changes, research, design tools etc)
  • Is there something in the design process that is lacking or needs more emphasis (loads description, rating methods, design tools
slide17

Panel Questions 2

  • Where do uncertainties exist in the loads, design, rating and system integration?
  • For prototype validation what should be tested/ validated/ verified to improve confidence in designs
  • What future research needs to be done to improve reliability