Академический Документы
Профессиональный Документы
Культура Документы
05 - September 2003
Special edition
In this issue:
Condition monitoring now certified for wind power plants WPP gears: broken tooth avoided WinTControl goes offshore No easy job: Aligning drive trains in WPPs Measurement location selection and diagnostics in WPPs Basics on the measurement of frequency spectra News & exhibition dates
brinell pitmarks which particularly influence the envelope spectra. Condition analysis using Flender diagnostic technology was recommended. Mr Westhoff, After Sales Manager of Winergy AG, authorized Flender Service to carry out mobile analysis of the gear condition
The diagnosis of the condition of the gear trains of wind power plants (WPP) is a most difficult task. Gusts of wind can cause sudden severe load fluctuations which can significantly affect the vibration behaviour. Diagnosis requires detailed information on the gear construction, the excitation frequencies that can be expected and a measurement technique that uses higher frequency and amplitude resolution. Also, an expert with sufficient diagnositic and service experience must be available. In fact, mobile condition monitoring technology can be used for WPP with a fixed RPM, but it is better still to install a suitable online condition monitoring system right from the beginning. The following example illustrates how the use of an unsuitable condition monitoring system impeded reliable condition diagnosis and the affected drive train gear could be saved by Flender Service just before a tooth broke. However, one thing after the other. A
and, if necessary, to perform a selective gear inspection using videoscopy. The initial date agreed for March 2003 for the on-site visit came about because of the lack of wind and the full calender of the parties involved. Before the inspection cover of the gear box was removed, measurements of the current condition were carried out using a DriveAnalysator. Strong acceleration excitations were visible in the envelope spectra, Cepstral analyses and in the time signals. As a result, an advanced local tooth damage was diagnosed on an intermediate shaft gear in the nacelle. Furthermore, the envelope spectra showed pulses from the output pinion gear that could be assumed to be standstill markings. Even after only a few glances two damaged teeth and the standstill markings could be seen during the gear inspection. The corner of a tooth was even threatening to break off. This confirmed the previous diagnosis made with the DriveAnalysator. The drive train was immediately brought to a halt in agreement with the plant manufacturer because the breakage of the corner of a tooth can lead to the immediate actual total loss of the gear. Unfortunately, the online system installed provided no information as to the trend of the damage and old data were no longer available. The gear unit was dismantled a week later by the plant manufacturer, and sent to Winergy AG in Voerde for further testing and repair. The diagnosis made in the nacelle was confirmed. The repair expense could be kept small due to the timely shutdown. The cause of damage was not clearly identifiable. Experience indicates that it is mostly short-time overloads during changeover, braking or during emergency stops which lead to such tooth damage.
Display of the tooth damage (see photo on right) in the time signal, in the Cepstrum and in the envelope spectrum.
listed on page 4. The acceleration transducers were specially developed by PRFTECHNIK for use on wind turbines. They exhibit a linear characteristic in the frequency range of 0.1 Hz to 10 kHz. The measurement signal in the frequency range of 0.1 Hz to 10 Hz is also available with a sensitivity of 1000 mV/g, so the smallest signal amplitude in the low frequency range can be seen at a high resolution. In the second WinTControl system, the condition monitoring and the diagnostics are divided into three levels. At level 1, the monitoring is based on monitoring the limits of broadband characteristic vibration values, at level 2 on monitoring the limits of diagnostic characteristic values (frequency selective) and, at level 3, on the diagnosis of changes in condition (condition diagnosis) on the basis of ordertracked amplitude spectra, envelope spectra and Cepstra, as well as time analyses and special procedures. The system calculates vibration levels from broadband vibration measurements on the drive train. The gear mesh frequencies of individual gear stages, the rolling bearing frequencies of the main bearing and the generator bearings are calculated and monitored as diagnostic characteristic values (level 2). The recording of level 3 measurement data is programmed so that measurements are carried out under comparable conditions and the diagnoses are carried out automatically and independently as
soon as a characteristic value is exceeded. The dependency of the vibrations on the prevailing operating conditions is taken into account on the basis of comparative measurements. The current measurement values are compared with warning and alarm limits and, if a violation occurs, a warning message is automatically sent by eMail or SMS to selected persons. In addition, the specialist can establish a connection to the system, analyze previous trends and/or perform special analyses. Both WinTControl systems are connected with one another in the nacelle via Ethernet and connected to the Internet via ADSL modem. As a result, the data can be accessed by all project participants at any time using an Internet browser. This provides operators, manufacturers and also insurers with the opportunity to simply gain an overview of the running and operating behavior of the wind power plant. This installation puts PRFTECHNIK Condition Monitoring at the forefront to also develop important basics for condition diagnosis and availability optimization of offshore wind power plants and to offer reliable online Condition Monitoring systems. Because, with respect to the revision clauses of the insurer that have recently come into effect (see article page 1), many operators must now equip their offshore systems with the most modern monitoring technology in order to obtain insurance protection. I
Application
thermal expansion must also be considered and alignment guidelines, either according to manufacturer data or as a result of experience and measurements, must also be taken into account. In addition, standard alignment tolerances are available for different RPMs. In the case of ships, there are other aspects to consider and the expression: alignment only in the early morning sun! holds true. The background to this is the warming up of the hull and the
is fully exploited. The alignment of the gear and generator of a WPP presents a comparable situation whereby there are also other additional problems to solve and difficult boundary conditions that have to be taken into account: Mounting the sensor components is difficult because the space is restricted by the brake. In cases of more severe misalignment, the laser beam can leave the mea-
Angular displacement (angular gap) Gap width referred to coupling diameter 100 mm
3000 1500
0.06 0.07
0.03 0.05
mode measurement records data while the shaft is rotating and just 60 of rotation is possible. Our experience dependent on the different types of WPP: The deformation of the nacelle plays a role in the alignment. Any change in the wind direction and wind strength can influence the alignment results. Depending on the operating mode, the generator and gear may be at different positions to one another during operation. The generator may sink over time due to aging of the vibration damper so that manufacturer data are required for corrections. With a little experience, it is quite possible to carry out alignment of the generator and gear while they are at a standstill. However, the question then arises as to whether this is also optimum for longer time periods or for different operating states. The optimum condition for alignment is obtained when the minimum reset forces of the coupling are reached during the normal operating state. Alignment data can be obtained either from the manufacturer of the WPP or as the result of measurements. WinTControl allows the optional connection of sensor components for the continuous monitoring of the alignment condition (PERMALIGN). This makes it possible to record the alignment condition depending on the operating state and the vibration behavior of the WPP . These measurements can be used to provide alignment target offsets for optimization of the shaft alignment. I
Amplitude spectra, envelope spectra with variable parameterization and Cepstren with a higher resolution Time wave forms / resonance frequencies Characteristic diagnostic values (v, a, env, cep) Characteristic vibration values (v, a, env, cep)
Amplitude spectra Intrinsic frequencies Characteristic diagnositic values Vibration characteristic values
scher Lloyd. The figure shown above illustrates how WinTControl is used. The diagnostic algorithms used also appear in the picture. The rolling bearings of generators, gears and main bearings, the toothing of the planetary stage(s) and helical gear stage(s) and the gondola, tower and special machine vibrations are monitored. In the case of variable speed systems, order spectra are used as standard. More details can be obtained under www.wintcontrol.com. I
Fig.: FEM calculation results which display different housing structure vibrations at three sample frequencies
6 6
Fig.: Vibration velocity spectrum of a planetary transmission with many harmonics from internal gear damage
Planet Counting teeth, RPM (example: stationary internal gear) Sun gear: z 1; nS [min-1] Planetary gears: z2; nP [min-1] Internal gear: z 3; Planetary carrier: nT [min -1] Number of planets: k Translation: i=z1/(z1+z3) Excitation frequencies Rotational frequencies Sun gear
Planetary gears
monics of the gear meshing in the frequency spectrum and pass frequencies and also to sidebands at a multiple of the damage frequency. In the diagnosis of planetary damage, the situation is aggravated by the fact that the special kinematics also causes a modulation effect even when the teeth are not damaged because the intermeshing planets cyclically approach the acceleration transducer fixed on the gear unit and move away again. Also, the pass frequencies are mostly very low frequencies which requires correspondingly long measurement times and suitable frequency analysis techniques. The resulting damage can be particularly well detected using envelope analysis although permanent online analysis with trend monitoring is recommended in order to record changes in condition that are already slight. I
gears proves to be considerably more time consuming. The adjacent info box lists the underlying calculation formulas for planetary gears with a fixed internal gear ring. Planetary gear units can also be operated in such a way that the planet carrier stands still, the sun gear stands still or even all gears turn (3-shaft operation). The current trend in gear trains is for two planetary stages to be arranged one after the other with a fixed internal gear. According to type and prominence, toothing faults can cause an amplitude modulation and/or phase modulation of the gear mesh frequency. Usually, this leads to an increase of the higher har-
Preview
Our next issue focuses on conveyor technology:
CM applications: Problem analysis on a bucket wheel excavator in the Amazon Technology: Experience with the application of wireless LAN in the telediagnosis of conveyor systems. Application: Condition monitoring of Polish giant strip mining equipment using modern Internet technology.
Planetary gears
Internal gear
News
Analyzing oil quality
Flender Service is offering a new service the analysis of oil quality. Especially the addition of EP and AW (ExtremePressure, AntiWear) additives has been tested in the case of high performance gear oils. This uses a new innovative measurement method which will shortly be released onto the market. Through the analysis of the smell alone, the type of oil which is used can be recognized, to indicate whether an inadmissible mixture is present or whether further addition is still OK. On the basis of our analysis, the operator of a WPP must be advised to dispose of his replacement oil, as a separation of the lubricant in the tank took place probably through the effects of the cold. Interested? Then contact us today!I
Imprint
PRFTECHNIK AG Postfach 12 63 85730 Ismaning www.pruftechnik.com Tel: 089-99616-0 Fax: 089-99616-200 eMail: info@pruftechnik.com Flender Service GmbH Sdstrasse 111 44623 Herne www.flender-service.com Tel: 02323-940-220 Fax: 02323-940-229 e-Mail: info@flender-cm.de
Dates
PRFTECHNIK AG and Flender Service:
The frequency pattern of the new wind transducer is linear above 0.1 Hz