Presented by CJ Crabtree, Dr. W Yang, Prof. PJ Tavner 22 nd January 2009

Transcription

1 Wind Turbine Condition Monitoring at Durham Summary of Durham Research to Date and into the Future Presented by CJ Crabtree, Dr. W Yang, Prof. PJ Tavner 22 nd January 2009

2 Test Rig - Synchronous Generator Synchronous Generator X & Y Proximeters Torque Transducer Gearbox DC Motor DC Tachometer Accelerometer(s) ~ Variable Speed Drive Resistive Load Banks Current & Voltage Transducers Instrumentation & Control Interface USB PC Running NI LabVIEW Data Acquisition & Control

3 Test Rig - Synchronous Generator

4 Results - Synchronous Generator connected 25 shorted connected shorted connected speed / rev/min 20 torque /Nm original torque signal denoised torque signal time /s C / N*m*min/re ev connected shorted connected shorted connected using original torque signal using denoised torque signal time /s

5 Results - Synchronous Generator speed / rev/min torq que /Nm no imbalance fault with imbalance fault original torque 180 denoised torque time /s C / N*m*m min/rev no imbalance fault with imbalance fault using original torque signal using denoised torque signal time /s

6 Test Rig - Induction Generator DFIG/WRIM (Generator) Mass Unbalance Plate X & Y Proximeters Torque Transducer & Shaft Tachometer Gearbox Mass Unbalance Plate DC Motor DC Tachometer Accelerometer(s) Grid Connection Resistive Load Banks (Rotor) 3 Phase Supply ~ Variable Speed Drive Current & Voltage Transducers USB Link Instrumentation & Control Interface (NI DAQ Pads) PC Running NI LabVIEW Data Acquisition & Control

7 Test Rig - Induction Generator

8 Characterisation - Real vs. Test Rig Comparison of Torsional Response of a Turbine Model and the Durham Test Rig Turbine Model Tower Frequency PSD (Power pe er Hz) 10 0 Turbine Model Response 10 0 PSD (Power pe er Hz) Test Rig Response Test Rig Natural Frequency Frequency (Hz) 10-6

9 Results - Induction Generator One phase to phase rotor resistance is changed marked abnormal Rotor and shaft mass imbalance results will follow over coming weeks

10 Interaction - Manchester University STFT Analysis of Stator Current Signal Obtained when an Open-Circuit Fault Occurs in the Stator. STFT Analysis of Generator Total Power Signal Obtained when an Open-Circuit Fault Occurs in the Stator.

11 Interaction - Industrial Partner (I) Data collected from an SKF condition monitoring system Known faults investigated Analysis of data from initial visit shows successful fault detection based on trend data Oil debris counts Gearbox vibration Additional data has recently been collected for analysis How do vibration and debris levels compare before and after maintenance? Is there consistency between turbines? The same SKF condition monitoring system is to be installed on The same SKF condition monitoring system is to be installed on the Durham Test Rig

12 Interaction - Industrial Partner (II) Gearbox intermediate shaft bearing fault Inspection confirms damage and bearing has been replaced Gearbox High Speed Shaft Axial Vibration Envelope (g) against Cumulative Energy Generated (kwh) Gearbox High Speed Shaft Transverse Vibration Envelope (g) against Cumulative Energy Generated (kwh) NB: Scale Change 01/08/ /09/ /11/2008 Bearing Replacement 01/08/ /09/ /11/2008 Bearing Replacement Initial damage causing increased vibration Severe bearing deterioration possibly causing reduction in vibration transmission path Initial damage causing increased vibration Severe bearing deterioration possibly causing reduction in vibration transmission path

13 Interaction - Industrial Partner (II) Gearbox intermediate shaft bearing fault Inspection confirms damage and bearing has been replaced Gearbox High Speed Shaft Axial Vibration Envelope (g) against Cumulative Energy Generated (kwh) Cumulative Ferrous 50 μm Bin Count against Cumulative Energy Generated (kwh) NB: Scale Change 01/08/ /09/ /11/2008 Bearing Replacement 01/08/ /09/ /11/2008 Bearing Replacement Initial damage causing increased vibration Severe bearing deterioration possibly causing reduction in vibration transmission path Increased particle count rate coinciding with change in vibration trend

14 Direction of Future Work To continue working with our industrial partners Collection and analysis of turbine data from the field Advance the test rig based on industrial information To converge work between Durham and Manchester Further development of test t rig fault-like lik perturbations ti Rotor mass imbalance emulating blade faults Emulate wind turbine gearbox damage Emulate wind turbine bearing damage Emulate generator mechanical faults Grid faults including grid synchronisation problems Instal SKF WindCon condition monitoring system on Test Rig Run SKF system in parallel with current DAQ system Compare test rig results with real turbine data

15 Published Work to Date W. X.Yang, P. J. Tavner and M.R. Wilkinson, Condition Monitoring and Fault Diagnosis of a Wind Turbine Synchronous Generator Drive Train, IET Journal of Renewable Power Generation, 3(1), 2009, p1-11. W. X.Yang and P. J. Tavner, Empirical Mode Decomposition, an Adaptive Approach for Interpreting Shaft Vibratory Signals of Large Rotating Machinery, Journal of Sound and Vibration, In Press, Wenxian Yang, P. J. Tavner and Michael Wilkinson, Condition Monitoring and Fault Diagnosis of a Wind Turbine with a Synchronous Generator using Wavelet Transforms, IET Power Electronics, Machines and Drives (PEMD2008), 2-4 April, York, UK, Wenxian Yang, P. J. Tavner and Michael Wilkinson, Wind Turbine Condition Monitoring and Fault Diagnosis Using both Mechanical and Electrical Signatures, IEEE/ASME International Conference on Advanced Intelligent Mechatronics (AIM2008), 2-5 July, Xi an, China, Wenxian Yang, P. J. Tavner, C. J. Crabtree, Research on a Simple, Cheap but Globally Effective Condition Monitoring Technique for Wind Turbines, XVIII International Conference on Electrical Machines (ICEM 08) 08), 6-9 Sept, Vilamoura, Portugal, Wenxian Yang, Jiesheng Jiang, P. J. Tavner, C. J. Crabtree, Monitoring Wind Turbine Condition by the Approach of Empirical Mode Decomposition, The 11th International Conference on Electrical machines and Systems (ICEMS 2008), Oct, Wuhan, China, Wenxian Yang and P. J. Tavner, Wind Turbine Condition Monitoring and Fault Diagnosis using Wavelet Transforms, the 4th PhD Seminar on Wind Energy in Europe, 1-2 Oct, Magdeburg, Germany, C. Crabtree and P. J. Tavner, Development Of A Test Rig For Condition Monitoring Offshore Wind Turbines, the 4th PhD Seminar on Wind Energy in Europe, 1-2 Oct, Magdeburg, Germany, Further journal and conference papers have been submitted for publication

16 Wind Turbine Condition Monitoring at Durham Any Questions?