Proactive Turbine Damage Reduction

Proac&veTurbineDamageReduc&on-Quan&fyingthevalueofreducingTransientLoads,

u&lizingalifecost-basedFMEAapproach

WebinarSeries

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q  This webinar will be available afterwards at www.windpowerengineering.com & email

q  Q&A at the end of the presentation q  Hashtag for this webinar: #WindWebinar

Before We Start

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Michelle Froese Senior Editor - Moderator Windpower Engineering

& Development

Dustin Sadler Principal Engineer AeroTorque Corp.

Doug Herr VP of Sales and Marketing

AeroTorque Corp.

Proactive Turbine Damage Reduction Meet your Presenters…

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1.  WhatisaTransientTorsionalEvent?2.   Howdoyoumi:gatedamagingTTEs?3.   Howdoesthisaffectturbinereliability?4.  WhatisthevaluetoyourCostofEnergy?

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•  Thedatashowsa50-70%reduc:onintheworstloadsfromtransienttorsionalevents

•  Thevalueofthosereduc:onstoyourturbinesandyourboHomline!

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TamingTorsionalLoadsintheWorld’sMostExtremeMachinesfor37Years.

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Thisisyourturbinemakingmoney!

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Example:BrakingProcedureduringaHardStop

NormalOpera&on

StoppingProtocolTriggered

CombinedAero-andCaliperDiscBraking

TorqueReversalwhenShaMStops

ThefinaltorquereversaloccurswhentheshaWstopsrota:ng!

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Anycontrolsystemreac:onrequiringrapidpitchingand/orstrongmechanicalbraking.

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•  E-stopsarenottheonlyhardstops.

•  E-stopsarenottheonlydamagingtypeofstoppingevents.

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Windsalsoini:atetransientloads!

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“ReverseTorsionalDamper”

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1.6MWTurbine

Ini:alSlipEventRemovesTorsionalEnergy

1

50-75%Reduc:onTorsionalOscilla&ons

2

75-100%Reduc:onReverseLoading

3

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TheseloadsarenotuniquetoanyOEM’sturbines!

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HardStopina1.65MWturbine

Ini:alSlipEventRemovesTorsionalEnergy

1

75-100%Reduc:onReverseLoading

3

50-75%Reduc:onTorsionalOscilla&ons

2

1.65MWTurbine

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TorsionalOscilla&onsandVibra&on*ShockloadsThroughtheTurbine*

2

TorqueReversal&ImpactLoading*TorsionalLoadingw/oRota:on*

3

Slippingbegins*LimitsMaxTorque*

1

1.6MWTurbine

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DuringTorqueReversals,loadzonesshiW180⁰.

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Calcula:onsshow25+yearlife.

Whyarebearingsfailingsooner?

90%CrackGenera&on

10%CrackPropaga&on

CrackGenera&on CrackPropaga&on Failure

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MOREthantheGearbox:Whatelseisaffectedbytransientevents?

•  MainBearings•  GeneratorBearings•  GeneratorRotor

Windings•  HighSpeedCoupling•  MainShaMtoHubBolts

•  RotorBlades•  BladetoPitchBearing

Bolts•  Electronics/Electrical

Systems•  Bedplate

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Recentcomple:onofthefirst,independent,non-OEM

FailureModesandEffectsAnalysis(FMEA)

oftheen:reTurbine.

WhitepaperandFMEAavailable.

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Sco^Eatherton,President,WindDrivenLLC.EmilMoroz,President,EMEnergyLLCDaveHeidenreich,P.E.,FounderandRe&redChiefEngineerofPTTech,Inc.Dus&nSadler,PrincipalEngineer,AeroTorqueCorpora&on

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#WindWebinar

High Speed Shaft Assembly

High Speed Intermediate Shaft Assembly

Low Speed Shaft Assembly

Low Speed Intermediate Shaft Assembly

ImagescourtesyofOlympus-IMSandNREL

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InternalSupport(hrs)

AverageLaborCost($/hr)

Totalinternalcosttorestorecomponent

function

ProjectedMeanTimeBetweenFailures/Repairs(yrs)

MeanCraneCost

($/event)

EstimatedDowntime(days/event)

EstimatedCostof

Downtime($/event)

Component

ExpectedUseful

TurbineLife(yrs)

CalculatedAnnualizedCostforRepairsor

Replacements

Totalexternalcosttorestore

componentfunction

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•  ActualCosts•  ActualRepairs•  ActualKW-hr•  ActualCapacity

Factors

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InternalSupport(Manhrs)

AverageLaborCost($/hr)

ProjectedMeanTimeBetweenFailures/Repairs(yrs)

MeanCraneCost

($/event)

EstimatedDowntime(days/event)

EstimatedCostof

Downtime($/event)

CalculatedAnnualizedValueforRepairsor

Replacements

Component

ExpectedUseful

TurbineLife(yrs)

Totalexternalcosttorestore

componentfunction

Totalinternalcosttorestorecomponent

functionProjectedFailuresinLifeofTurbine(yrs)

CredibilityofEvidencethatlinksTTEstofailuremode

ContributionTowardsFailure(percentage)

EstimatedLifeExtension

(percentage)

EstimatedNewTimeBetween

Failures(yrs)

FailureModesthatcanbemitigatedbyareductioninTransientTorqueEvents(TTEs)

ProjectedLifeImprovementforaWindTCinMitigatingTTEDamageProjectedAnnualizedValueattributedtothe

WindTC

AssumingNoDowntime(nosoftcosts)

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Over$11,000annualvalueofthereduc:oninloadstoGearboxComponentsalone,notcoun:nglostproduc:on

GearboxHighSpeedShaftAssembly

(HSS)20 5 $5,264 BearingFatigue-Surface&Subsurface-Macropitting $3,458.89 $2,102.52

GearboxHighSpeedIntermediateShaftAssembly(HSIS)

25 10 $6,095 BearingFatigue-Surface&Subsurface-Micropitting $3,054.85 $2,232.03

GearboxLowSpeedIntermediateShaftAssembly(LSIS)


GearboxLowSpeedShaftAssembly(LSS)


$13,785 $11,108

AssumingNoDowntime(nosoftcosts)

GEARBOXCOMPONENTS

Component

ExpectedUseful

TurbineLife(yrs)

ProjectedMeanTimeBetweenFailures/Repairs

(yrs)

CalculatedAnnualizedCostforRepairsor

Replacements

FailureModesthatcanbemitigatedbyareductioninTransientTorqueEvents(TTEs)

ProjectedAnnualizedValueattributedtothe

WindTC

$13,785 $11,108

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Annualized“hard”value:Over$12,600peryearinstalledWithlostopportunity“soWcosts”,suchaslostproduc:on,thevaluegrowsto$15,000

Component ExpectedUsefulTurbineLife(yrs)

ProjectedMeanTimeBetweenFailures/Repairs

(yrs)

CalculatedAnnualizedCostforRepairsorReplacements

ProjectedAnnualizedValueaHributedtothe

WindTC

ProjectedAnnualizedValuewithoutDown:me

GEARBOXCOMPONENTSGearboxHighSpeedShaWAssembly

(HSS) 20 5 $5,264 $3,458.89 $2,102.52

GearboxHighSpeedIntermediateShaWAssembly(HSIS) 20 10 $5,748 $3,054.85 $2,232.03

GearboxLowSpeedIntermediateShaWAssembly(LSIS) 20 10 $5,748 $2,391.93 $2,139.11

GearboxLowSpeedShaWAssembly(LSS) 20 15 $9,766 $4,879.69 $4,633.98

TOTALANNUALVALUETOGEARBOX $13,785 $11,108

OTHERDRIVETRAINCOMPONENTS

MainShaWBearings 20 15 $15,272 $1,189.24 $1,108.86GeneratorBearings 20 8 $1,626 $28.99 $24.06

GeneratorRotorWindings 20 10 $14,628 $91.63 $81.93HighSpeedCoupling 20 15 $841 $282.66 $233.09RotorBladeRepair 20 8 $3,111 $35.10 $29.90

MainShaWtoHubBolts 20 20 $8,651 $15.56 $15.36BladetoPitchBearingsandBolts 20 20 $5,068 $16.68 $15.83

TOTALANNUALVALUETOOTHERDRIVETRAINCOMPONENTS $1,660 $1,509

OTHERTURBINECOMPONENTSTowerRepairs/TowerBolts/

AnchorBolts 20 20 $1,484 $0.15 $0.13

Electronics/ElectricalSystems 20 2 $2,306 $3.45 $1.80PowerCables 20 20 $2,838 $0.00 $0.00Bedplate 20 25 $7,818 $14.06 $12.57

TOTALANNUALVALUETOOTHERTURBINECOMPONENTS $18 $15 TOTALANNUALVALUETOENTIRETURBINE $15,462.88 $12,631.17

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CurrentAnnualRevenue/Turbine

Ifwecanjustincreaseavailability1%...

Addi:onalRevenue=$3,700/turbine/year

$0.08(Rate) X32%(Capacity) X97%(Availability)X365daysX24hrsX1.65MW =$359K

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Down:meismoreexpensivethanmostpeoplethink!

Down:mecostsyou$1,000aday/turbine/average

Down:meduringproduc:onCostsyou$3,000/day!

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•  Transientloadingisgoingoninyourturbines,likelymoreoWenthanexpected

•  Theseloads/eventscancauselong-termdamagetoyourturbines

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•  Thereisasolu:onthataddressesmanyoftheeffectsoftheseloadsbyreducingtheenergystoredinthesystem

•  Thissolu:onshowsareturnoninvestmentofover$15,000/year,givingapaybackoflessthanayear

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1.   ReviewWhitePaper&FMEA–thiswillbesenttoallwebinaraHendees.

2.   ContactAeroTorqueforyourcustomizedROIforyourfleetandfailuremodes.

3.   Setupamee:ng–Yoursiteorours.

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Michelle Froese Senior Editor - Moderator Windpower Engineering & Development [email protected] @Windpower_Eng Dustin Sadler

Principal Engineer AeroTorque Corp. [email protected] @AeroTorque

Doug Herr VP of Sales and Marketing AeroTorque Corp. [email protected] @AeroTorque

Proactive Turbine Damage Reduction Questions?

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Thank You q  This webinar will be available at

www.windpowerengineering.com & email

q  Tweet with hashtag #WindWebinar

q  Connect with Windpower Engineering & Development

q  Discuss this on EngineeringExchange.com

Proactive Turbine Damage Reduction

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