“7th Canadian German Conference on Wind Energy“ Montreal – February 8, 2011 – Le Centre Sheraton
State-of-the-art Alignment and Vibration Monitoring Technologies for Wind Turbines Mr. Florian Buder Managing Director – PRÜFTECHNIK Canada
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
Content ►Who is PRÜFTECHNIK? ►Profitability of Wind Power Plant ►Why shaft and geometrical alignment? ► ROTALIGN® Ultra: Expert Alignment of drive trains ► INCLINEO®-LEVALIGN®: Foundation levelness, plumbness ► PERMALIGN® or ROTALIGN® Ultra - Live Trend : Dynamic Displacement Monitoring
►Benefits of Condition Monitoring ► VIBXPERT® II: Portable Vibration analysis ► Route based condition monitoring ► Balancing of Wind Turbines ► VIBROWEB XP®: Certified Online Condition Monitoring ► 7 different results, examples ► WEARSCANNER®: Oil Particle Counting
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
January 26 2010
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Who is PRÜFTECHNIK?
PRÜFTECHNIK is an independent system supplier of condition monitoring, vibration and alignment equipment. PRÜFTECHNIK is the inventor of laser shaft alignment systems. PRÜFTECHNIK is represented in 70 countries around the world and supplies sensors, hardware and software for rotating machinery in all industries. PRÜFTECHNIK offers a worldwide machinery service and has its own Monitoring Center certified by the Germanische Lloyd.
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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Profitability The profit of a wind power plant is defined by... Wind speed Price per kW/h Uptime of the wind power plant
Uptime = Annual available hours - Downtime Maintenance Downtime - Repair & replacement - ... Operating Downtime - Calm - Storm - Machine failure © 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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Why Shaft and Geometrical alignment? Your benefits …
Higher plant efficiency ► Asset protection ■ Low vibration ► Reduction of the maintenance cost ■ Less repair ■ Less spare parts consumption ► Higher productivity ■ Longer machine availability ■ Higher reliability
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
January 26 2010
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Alignment of wind turbines Reliability starts with precision gearbox generator shaft alignment Blades
Accurate shaft alignment is an important factor towards preventing premature damage in rotating machinery. It increases the operating lifespan of such machinery. Shaft alignment systems from PRÜFTECHNIK take hundreds of readings, making it possible to perform the measurement under space constraints with the highest accuracy.
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
Gearbox Alignment task: Coupling alignment between gearbox and generator
Generator
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ROTALIGN® Ultra Shaft Highest standards in machinery alignment ► ROTALIGN® Ultra is a high end modular alignment system. Its unique features and performance meets the most demanding requirements when carrying out alignment jobs ► ROTALIGN® Ultra uses a unique measurement principle that allows the machine correction to be monitored simultaneously in both horizontal and vertical directions ► ROTALIGN® Ultra computer features a new 5.7-inch colour TFT sunlight readable full VGA screen ► ROTALIGN® Ultra is a multifunctional platform with shaft and geometric applications running on a user friendly interface © 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
Alignment Procedure Quick and straightforward! Precision laser alignment in 3 steps Enter dimensions Define machine dimensions with the aid of the large LCD display
Measure After on screen laser adjustment, rotate shafts
Display results Alignment condition at the coupling and the machine feet corrections are displayed on screen © 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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INCLINEO®-LEVALIGN®: Foundation levelness, plumbness ► Foundation levelness plays a decisive role ► The plumbness of the entire tower ► The mating surfaces of tower segments must be flat and parallel to ensure proper assembly. ► The large cam wheel mounted on top of the tower must be checked for flatness ► The nacelle-hub assembly possesses several flanged surfaces Depending on the measurement task, LEVALIGN® laser measurement system or the high precision electronic inclinometer INCLINEO® are applied
1 Hub 2 Cam wheel 3 Tower segments 4 Foundations © 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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PERMALIGN® or ROTALIGN® Ultra - Live Trend Determining alignment targets
Cold alignment targets may not accurately predict the actual operating condition of a running machine. The ROTALIGN Ultra Live Trend module or the PERMALIGN monitors movement of machines during run-up or coast-down phase, in order to determine the positional change over time and the influences of given events. The measured changes are used for thermal growth compensation when aligning the machines in cold condition. Results are transferred and analyzed with ALIGNMENT CENTER - PC Software
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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Benefits of Condition Monitoring
C O S T
Problem Detection
Problem Communication
Problem Analysis
Correction
Without Condition Monitoring
With CM
TIME
Increased Plant Availability Optimum Plant Performance Reduced Maintenance Costs Improved Safety
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
January 26 2010
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Why Condition Monitoring on WPP*? Eliminate unscheduled bearing and gear related maintenance activities Helps to schedule maintenance during low or no-wind periods Reduces the number of site visits for mechanical assessments Reduce overtime expenses and production losses Perform condition-based repairs up the tower Reduce crane time Reduce overload Eliminate secondary damage Extend machine Asset Life Reduce component inventories and *WPP = Wind Power Plant consumption rates © 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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Vibration influences on wind turbines Machine vibrations • • • •
Gear and generator vibrations Nacelle and main bearing vibrations Imbalance (rotor blades, brake disc) Alignment error
Aerodynamic vibrations • Airborne noise and vibrations • Pitch error • Blade pass frequency
Blade lag Drive train torsion Nacelle tilt
Tower bending Blade flap
Electrical vibrations • Bearing structure vibrations • Electromagnetically generated vibrations • Converter and controller-based vibrations
Tower torsion
Frictional vibrations • Roller bearing damage • Shaft rubbing
Additional vibrations • Azimuth and pitch vibrations • Vibrations from auxiliary machines © 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
Natural vibrations • Structural vibrations (tower, rotor blades) • Torsional vibrations • Bending and axial vibrations 13
VIBXPERT® II: Offline - Route based condition monitoring
Routes are setup in OMNITREND® and downloaded to VIBXPERT® Tree structure is displayed for ease of navigation through route Data is stored and analysed in OMNITREND®
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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VIBXPERT® II is used for Dynamic Balancing of Wind Turbine Rotor Blades Measurement procedure Attach test weight Measure influence of test weight Attach balancing weight Measure residual imbalance Repeat balancing steps until vibration levels are acceptable
Before balancing
After balancing
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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Online Continuous Monitoring with certified VIBROWEB® XP Online System
CONTROL CABINET PLC
COMMUNICATION Signals (4-20mA…) Wind speed, motor power,…
Fiber Optic Ethernet 10BaseT
Galvanic separation
Wireless (WLAN…) Cellular telephony (GPRS…) Ethernet LAN
POWER SUPPLY Power supply of CMS via UPS Displacement
SENSORS RPM
The number of sensors is dependent on the type of turbine.
Accelerometer
Sensors used: Accelerometer sensor Displacement sensor RPM sensor © 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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Result 1: Increased Vibration on the Generator TeleMonitoring continuously records vibration changes and monitors vibration trends.
Generator problem
VDI 3834 will appear early 2009
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
Generator damage leads to increased vibrations
28/10/2009
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Result 2: Misalignment between Generator and Gearbox TeleMonitoring continuously records vibration changes and documents successful service measures such as the alignment corrections shown here. 10 mm/s
6 mm/s Marked reduction in vibration after alignment correction !!
VDI 3834 will appear early 2009
Vibration velocities drop after realignment
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
28/10/2009
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Result 3: Inner Race Defect – Intermediate Gear Stage
TeleMonitoring continuously records vibration changes and uses envelope spectra for roller bearing condition diagnoses.
a [m/ s²]
W EA 80007\ M Gearbox Metso\ A_5, GB intermediate stage, 45 °\ 10 11 HA450Hz60s_ F 18 .10.2006 08:24:35
0,95 0,90 0,85 0,80 0,75 0,70 0,65 0,60 0,55 0,50 0,45 0,40 0,35 0,30 0,25 0,20 0,15 0,10 0,05 0,00
Example of inner race defect, IMS gear
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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100
150
200
250
300
350
400
450 f [Hz]
Monitoring the amplitudes of the inner race frequency
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Result 4: Outer Race Defect – Generator TeleMonitoring continuously records vibration changes and can even identify advanced bearing damage when the system is commissioned.
Time waveforms, envelope spectra and amplitude spectra in OMNITREND
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
28/10/2009
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Result 5: Gear Mesh Frequencies
TeleMonitoring continuously monitors vibration changes and evaluates trends in the component-specific gear conditions. IMS (117.3 Hz) and HS (402.2 Hz) GMF with a the high stage shaft rotate speed (18.2 Hz) as predominant signal, the amplitudes will be monitored with CMS permanently
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
28/10/2009
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Result 6: Pre-damaged toothing – 0 to 200Hz Band axial TeleMonitoring continuously records vibration changes and monitors pre-damaged toothing for unusually rapid deterioration.
Local tooth damage in the intermediate stage.
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
28/10/2009
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Result 7: Stillstand Marks - Sidebands
TeleMonitoring continuously records vibration changes and monitors stillstand marks for changes.
Side bands in vibration velocity spectrum Prominent stillstand mark in a gear; this may lead to tooth breakage.
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
28/10/2009
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WEARSCANNER®: Oil Particle Counting Recognizes bearing & gear teeth damage Avoids consequential damage Enhances the availability of the machine How does it work: The WEARSCANNER® measures the number of particles and the particle sizes online to monitor wear. It can be assumed that there is a direct relationship between the particle size distributions and the wear rate, or the machine damage level. It is useful to supplement Condition Monitoring (based on vibration measurement) with sizedependent particle counting. This makes it possible to more effectively monitor low-speed components. In the event of preliminary damage, progressive damage can be tracked without requiring time-consuming videoscopy.
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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10 ►Ten years of experience in the wind sector have provided PRÜFTECHNIK with a high level of expertise.
100 ►100 Hundreds of wind turbines around the world are monitored by the PRÜFTECHNIK Monitoring Center.
1 000 ►Thousands of wind turbines worldwide are equipped with PRÜFTECHNIK systems.
1 000 000 ►Millions of additional kilowatt-hours of current can be fed into the power grid by our customers as their turbines become less subject to unscheduled downtime. © 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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Questions? - Thank you
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Questions? - Thank you for your attention! www.pruftechnik.ca -
© 2011 PRÜFTECHNIK Canada Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
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