“7th canadian german conference on wind energy“ -...

© 2011 PRÜFTECHNIK CanadaCertain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications

“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 TurbinesMr. Florian Buder

Managing Director – PRÜFTECHNIK Canada

© 2011 PRÜFTECHNIK CanadaCertain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications January 26 2010 2

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 CanadaCertain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications 333

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.

Who is PRÜFTECHNIK?


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

Profitability


► Asset protection

■ Low vibration

Why Shaft and Geometrical alignment?

Your benefits …Higher plant efficiency

► Reduction of the maintenance cost

■ Less repair

■ Less spare parts consumption

► Higher productivity

■ Longer machine availability

■ Higher reliability


Alignment task:Coupling alignmentbetween gearboxand generator

Blades

Gearbox

Generator

Alignment of wind turbines

Reliability starts with precision gearbox generator shaft alignment

� 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.


ROTALIGN® Ultra ShaftHighest 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


Alignment ProcedureQuick and straightforward! Precision laser alignment in 3 steps

Measure

After on screen laser

adjustment, rotate shafts

Display results

Alignment condition at

the coupling and the

machine feet corrections

are displayed on screen

Enter dimensions

Define machine dimensions

with the aid of the

large LCD display


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 inclinometerINCLINEO® are applied

1 Hub

2 Cam wheel

3 Tower segments

4 Foundations


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.

PERMALIGN® or ROTALIGN® Ultra - Live TrendDetermining alignment targets

Results are transferred and

analyzed with ALIGNMENT

CENTER - PC Software


� Increased Plant Availability

� Optimum Plant Performance

� Reduced Maintenance Costs

� Improved Safety

COST

TIME

With CM

Without Condition Monitoring

Problem Detection

Problem Communication

Problem Analysis

Correction

Benefits of Condition Monitoring


�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 consumption rates *WPP = Wind Power Plant

Why Condition Monitoring on WPP*?


Vibration influences on wind turbines

13

Aerodynamic vibrations• Airborne noise and vibrations• Pitch error• Blade pass frequency

Machine vibrations• Gear and generator vibrations • Nacelle and main bearing vibrations• Imbalance (rotor blades, brake disc)• Alignment error

Frictional vibrations• Roller bearing damage• Shaft rubbing

Natural vibrations• Structural vibrations (tower, rotor blades)• Torsional vibrations• Bending and axial vibrations

Electrical vibrations• Bearing structure vibrations• Electromagnetically generated vibrations• Converter and controller-based vibrations

Additional vibrations• Azimuth and pitch vibrations• Vibrations from auxiliary machines

Blade flap

Tower torsion

Drive train torsion

Blade lag

Nacelle tilt

Tower bending


VIBXPERT® II: Offline - Route based condition monitoring

14

�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®


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

VIBXPERT® II is used for Dynamic Balancing of Wind Turbine Rotor Blades


Online Continuous Monitoring with certified VIBROWEB® XP Online System

Accelerometer sensor

Displacement sensor

RPM sensor

Sensors used:

Accelerometer

RPM

Displacement

SENSORS�

Galvanic separation

PLC

CONTROL CABINET�

Signals (4-20mA…)Wind speed, motor power,…

� POWER SUPPLY

Power supply of CMS via UPS

Ethernet 10BaseTFiber Optic

COMMUNICATION�

Wireless (WLAN…)

Cellular telephony (GPRS…)

Ethernet LAN

The number of sensors is dependent on the type of turbine.

© 2011 PRÜFTECHNIK CanadaCertain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications 28/10/2009 17

Result 1: Increased Vibration on the Generator

Generatorproblem

TeleMonitoring continuously records vibration changes and monitors vibration trends.

VDI 3834 will appear early 2009 Generator damage leads to increased vibrations


Result 2: Misalignment between Generator and Gearbox

Vibration velocities drop after realignment

Marked reduction in vibration after alignment correction !!

VDI 3834 will appear early 2009

TeleMonitoring continuously records vibration changes and documents successful service measures such as the alignment corrections shown here.

10 mm/s

6 mm/s


Result 3: Inner Race Defect – Intermediate Gear Stage

50 100 150 200 250 300 350 400 450f [Hz]

0,00

0,05

0,10

0,15

0,20

0,25

0,30

0,35

0,40

0,45

0,50

0,55

0,60

0,65

0,70

0,75

0,80

0,85

0,90

0,95

a [m/ s²] WEA 80007\ Gearbox Metso\ A_5, GB intermediate stage, 45°\ 1011 HA450Hz60s_F 18.10.2006 08:24:35WEA 80007\ Gearbox Metso\ A_5, GB intermediate stage, 45°\ 1011 HA450Hz60s_F 18.10.2006 08:24:35WEA 80007\ Gearbox Metso\ A_5, GB intermediate stage, 45°\ 1011 HA450Hz60s_F 18.10.2006 08:24:35WEA 80007\ Gearbox Metso\ A_5, GB intermediate stage, 45°\ 1011 HA450Hz60s_F 18.10.2006 08:24:35M

Example of inner race defect, IMS gear

TeleMonitoring continuously records vibration changes and uses envelope spectra for roller bearing condition diagnoses.

Monitoring the amplitudes of the inner race frequency


Result 4: Outer Race Defect – Generator

Time waveforms, envelope spectra and amplitude spectra in OMNITREND

TeleMonitoring continuously records vibration changes and can even identify advanced bearing damage when the system is commissioned.


Result 5: Gear Mesh Frequencies

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

TeleMonitoring continuously monitors vibration changes and evaluates trends in the component-specific gear conditions.


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.


Result 7: Stillstand Marks - Sidebands

Side bands in vibration velocity spectrum

TeleMonitoring continuously records vibration changes and monitors stillstand marks for changes.

Prominent stillstand mark in a gear; this may lead to tooth breakage.


� 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 size-dependent 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.

WEARSCANNER®: Oil Particle Counting


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.


Questions? - Thank you

- Questions? - Thank you for your attention!

- www.pruftechnik.ca

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