Reliability Analysis And Condition

Nonitoring of a Horizontal Axis Wind

Turbine
Muhammad Mohsin K Khan
M.Engineering Thesis Presentation
Faculty of Engineering and Applied Sciences
MUN, St.Johns .NL. CANADA, A1B 3X5
Contents of Presentation
Condition Nonitoring - Overview of previous
work
Problem Statement
System Description
Reliability modeling and Analysis
Reliability Analysis results and identification of
problems
Condition Nonitoring System Design
CN System !mplementation
Conclusion and Recommendations
Previous Work in CN for Wind Turbines
Nany Researcher have done work in several directions
P Caselitz and Giebhardt have worked for several years
in Germany on CNS for WTs
!nstitute for Solar Energy
Tech !SET Germany
Discussed the CN
development of a 600 kW
WT
Remote Access is used by
interconnecting the data
acquisition module and PC
Separate PC for
Data acquisition
Pricing !ssue for
Smaller WTs
A solution is
required. !
Previous Work in CN for Wind Turbines
Purpose of Research - Problem Statement
An efficient and cost effective solution for CN
CN can not be Generic initially
CN cannot monitor every thing without a
reason. !
To !dentify the components that will require
CN a in-depth Reliability Analysis is required
AOC 15f50 - Wind
Turbine System
-50 K Watt system
-Downwind , Stall
regulated
-Passive yaw
-Cut-in wind speed
+.6mfs
-Cut-out wind speed
22.+mfs
-Rated power 50Kwatt
@12mfs and up.
AOC 15f50 components
System Description and components
Drive Train
Nethodology adopted for
Reliability Analysis
The steps
carried out to
conduct the
analysis
depicted in the
flow chart.
Select Failure Model
Failure Nodes
Reliability Analysis require failure rate data for all
components.
FN Dependent on Working environment of
component.
FNEA and Selection of Reliability Nodels
System failure
System failure
Degraded
Performance
Unable to stop.
System Failure
System Failure
2 Brakes Failed
= Sys Failure
2 Bolts Failed =
System Failure
System failure
System failure
Consequences RA Nodel Failure Nodes Components
Random Failure Nodel
Random Controller
Physical Reliability
Nodels
Fatigue Tower
Wiebull Reliability
Nodel
Fatigue Yaw bearing
Wiebull Reliability
Nodel
Fatigue Parking breaks
Random Failure Nodel
Random Gearbox
Random Failure Nodel
Random Generator
Wiebull Reliability
Nodel
Fatigue Aerodynamic
Breaks
Physical Reliability
Nodels
Shear
failurefFatigue
Bolts
Physical Reliability
Nodels
Fatigue Hub
Physical Reliability
Nodels
Fatigue Blade
Exponential Reliability Nodel (Random
Failures)
R(t) = e
-t
Wiebull Reliability Nodel
R (t) = exp -(tf)

Physical Reliability Nodel

Governed by Stress distribution and Strength
characteristics of a component
Reliability Analysis - Reliability Block diagrams

= R
Rotor
x R
D_Train
x R
Support
x R
Controller
3 - Components are Analyzed using CFR.
Generator
Gearbox
PLC
Failure Rate for Generator
(t) = 0.796 x 10
6
/ hr
R(t) = 0.997 for t = 8760 hrs (1 year)
Reliability Analysis - RANDON FA!LURES
3- Component Failing due to Fatigue - Wiebull
Reliability model.
Failure data available for Yaw bearing: Data
Nanipulation required for Tip and Parking
brake
Tip Brake:
= 100.00 x 10
6
/hr => MTTF = 10,000 hrs
Using Modeling Equation for Wiebull Model
MTTF = (1 + )
Reliability Analysis - T!NE DEPENDANT FA!LURES

1
Unknown parameters - Selection of (shape
parameter) value with regards to following
table.
Table for values (Ebeling 1997)
Reliability Analysis - T!NE DEPENDANT FA!LURES
Values Property
0<<1 Decreasing Failure rate DFR
=1 Exponential Model or Random
Failures
1<<2 Increasing Failure rate IFR
=2 Linear Failure: Rayleigh Distribution
Model
>2 Increasing Failure rate IFR
3<<4 FR Values approach Normal
distribution
= 1.85 for Tip breaks.
0 = 11260 Hrs
MTTF = (1 + )
R(t) = 0.533+ @ t = 8760 hours
Similar approach is used to determine the
Reliability for Parking Brakes with = 2.2
Reliability Analysis - T!NE DEPENDANT FA!LURES

1
Blades, Bolts, HUB.
!nvolve Two main Step.
1. Static Nodeling.
2. Dynamic Nodeling.
Static Nodel - specifying the failure mechanics
, Structure type.
Nany model available - here used CONSTANT
Strength and RANDON Stress Nodel.
Reliability Analysis - Physical Reliability Nodels
Blades.
R = o( Ln )
s= shape parameter for lognormal
stress distribution taken to 0.1
k = Strength of Naterial
x
mode
= x
med
fexp (s
2
)
x
mode =
Naximum Stress
Reliability Analysis - Physical Reliability Nodels
s
1
med
x
k
Stress on Blade Root
T = C
T
R U (Nanwell 2002)
N

= [1f2 8f9U 2r| dr (Nanwell 2002)

N

= R

max
= N

Reliability Analysis - Physical Reliability Nodels

R
r
0
B
1
B
T
3
2
b
I
C
R = o( Ln )
For Dynamic Reliability (Periodic Loading)
R = exp
(1 R) t
(Ebeling 1997)
Loading Model for WT Blades (Manwell 2002)

L
= 60 K n
rotor
H
op
Y
R
blade
= 0.9068
Similar Procedure : Bolts, Hub & Anchor Bolts
Reliability Analysis - Physical Reliability Nodels
Static and Dynamic Nodeling
s
1
med
x
k
Narkov model predict
on basis of reliability
data how likely the
system is going to be in
a certain state.
Narkov Analysis
Standard Narkov Equation
P
1
(t) =e
- (1 +2 +3 + 5) t
P
2
(t) = e
-(1 + 2) t
- e
-( 21 + 2 ) t
P
3
(t) = e
-2 t
- e
-(+2) t
P
+
(t) = e
- (+ + 2) t
- e
-(3++ + 2) t
P
5
{t) = 1-P
2
(t) - P
3
(t) -P
+
(t) - P
1
(t )
Narkov Analysis
S.No State of System Probability @ t =
8760
Probability @ t = 8076
x2
1 P
1
(t) 0.3326 0.1106
2 P
2
(t) 0.035 0.0024
3 P
3
(t) 0.3868 0.1725
4 P
4
(t) 0.0395 0.309
5 P
5
(t) 0.2066 0.68294
On the basis of model we have the individual
probabilities of being in every state.
Fault Tree Analysis
Probability of Top Event P{T) = System
Failure
P (T) = F
rotor
U F
controller
U F
derive train
U F
tower suppor
P (T) = [F
blades
U F
bolts
U F
Hub
U F
tipbrk
] U [F
Controller
] U
[F
generator
U F
gearbox
U F
parkingbrk
] U [F
yaw
U F
tower
]
P(T) = 0.6427
R(T) = 1 P(T)
R(T) = 0.3573
Markov Analysis
33.26% availability in first year of
installation the results for both
are fairly close
Reliability Analysis Result and !dentification of
Problematic Components
1.000 x 10
-7
R = 0.99970
Tower and
Anchor Bolts
1.116 x 10
-5
R = 0.90680
Hub
1.116 x 10
-5
R = 0.90680
Bolts
1.116 x 10
-5
R = 0.90680
Blades
2.16 x 10
-6
R = 0.9990
Parking Brake
0.63 x 10
-6
R = 0.99++0
Gearbox
0.769 x 10
-6
R = 0.99305
Generator
0.115 x 10
-4
R = 0.90130
Yaw Bearing
1.00 x 10
-4
R = 0.533+0
Tip Brake
Failure rates Reliability Component
Adopted Nethodology for CN System Design
visual inspection Structural
component
9. Tower and
Anchor Bolts
visual inspection Structural
component
8. Hub
visual inspection Structural
component
7. Bolts
visual inspection Structural
component
6. Blades
visual inspection Wear out but
longer life
5.Parking Brake
Vibration
Monitoring
Random Failure -
Low sensitivity
+. Gearbox
Vibration
Monitoring
Random Failure -
Low sensitivity
3. Generator
Strain
Measurement
Highly Sensitive -
Wear out Effects
2. Yaw bearing
Current
Sensing
Highly Sensitive -
Wear out Effects
1. Tip Brakes
Selected
Parameter
Sensitivity Component
Parameter Selection for
components
Experimentation and Analysis for CN system
Design
Some Experimentation and
Analysis was performed
before proceeding toward
the system design
An Inherent Imbalance of
Mass was observed on the
Derive Train
= 9.65 x 10
-7
m/m
R = . (GF) .R
R = 0.009118
V R
Vibration Monitoring Drive
Train
Proposed CN system Block Diagram
The Proposed CN setup(Test Bench) will be able
to provide Signals for three parameters strain,
current and vibration.
The System: Electronic interfaces 8 !ndependent
SBC
Sensors Selection (Current - Tip Brake)
Power Supply- Tip
brake: 0-5Af120vAC
Sensor Detecting
Range.
Dynamic Operation
Range in Harsh
Environments
SCD05PUN - CU! !nc
Sensors Selection (Strain - Yaw Bearing)
Netal Strain Gauge
Bridge Configuration
Half Bridge
configuration
GF = 2.0; R = 120O
Two Gauges provide
Temperature
Compensation
Sensors Selection (vibration Analysis)
Piezoelectric sensors are typically used.
Sensor Detecting Range (Frequency).
Dynamic Operation Range in Harsh Environments
ACH-01: Nanufactured Neasurement Specialist Ltd"
Layout Design of !nstrumentation Board
Based on Selected Sensor the following Layout was
designed to capture the signals and Acquire Data for
analysis and Nonitoring.
Test Bench Setup
Signals Source -
Test Bench Setup
for three parameters
Current variation Setup
Strain variation Setup
vibration Signal source
Designed !nstrumentation Board
Board Operate at supply of + 15 volts DC
Separate on board supply setup for Current
Sensor
Output signal protection for analog channels
Single Board Computer (SBC)
JK-micro system Pico
Flash digital board
Pico Flash - Pico !fO
analog expansion
Equivalent to !ntel 186
processor
Built in Dos Env.
C and C++ lib
12 bit 11 analog
channel and 2 digital
ports for output and
input
!nterfaced with LAPTOP
using HyperTerminal
Signal conditioning and Calibration - Strain
!nput Strain vs Output voltage
DC - offset
Y {strain) = 0.0064 x
3
- 0.052 x
2
+ 0.14 x - 0.11
Signal conditioning and Calibration - Current
!nput Current vs Output voltage
DC - offset
Y {current) = 0.112x
5
-1.656x
4
+9.432x
3
-
25.72x
2
+34.05x -16.2S
!nterface and Calibration - vibration
!nterface provided with
datasheet
DC - offset for complete signal
capture
vibration Analysis and FFT result
DFT is required
DFT computation takes N
multiplication and N(N-1)
additions to compute
Smart FFT computation
routine - Butterfly algorithm
Routine adopted from
Literature
Total computation << 1 sec
for N = 256 sample window
Condition Nonitoring Routine
Routine written in C++
Noving Average window
for Current samples
!nstantaneous Strain
Sampling
FFT computation for Nf2
frequency harmonics
!nterrupt for PLC
Concluding Remarks
Reliability Analysis for AOC15f50- Design of LOW cost CN
system
Reliability Analysis similar to result of other researchers
Life time vs Environment
Unavailability of Failure data related to Wind Engineering
System is less then 50 reliablefAvailable
CN system design based on RA: Different Failure data may
suggest a different design
CN system may perform differently when mounted on
AOC15f50
voltage Drift in Current Sensor
SBC capable of handling more parameters
vibration analysis: Average magnitude of spectrum
Recommendations for !mprovement
Precise Wind Turbine part data.
Further Detailed Reliability Analysis
Field Test for CN system
LAN capabilities of SBC
!mproved Current Sensor is required
+ setups of strain
Detailed in vibration analysis
FFT Range and Resolution
Thanks And Acknowledgements
Ny Supervisors: Dr. Tariq !qbal and Dr. Faisal
Khan
Professors at Faculty
Friends
Questionsf Discussion