PROTEST -Procedures for Testing and Measuring Wind Energy Systems Drive train case study Holger Söker, DEWI GmbH SITE ASSESSMENT. WIND TURBINE ASSESSMENT. GRID INTEGRATION. DUE DILIGENCE. KNOWLEDGE. CONSULTANCY
PROTEST - Participants Page 1 Participant organisation name Energy Research Centre of the Netherlands ECN NL (Coordinator) DEWI GmbH - Deutsches Windenergie-Inst. DEWI DE Center for Renewable Energy Sources CRES GR Hansen-Transmissions International Hansen BE Suzlon Windkraft GmbH Suzlon DE/INDIA Germanischer Lloyd Industrial Services GmbH GL DE Universität Stuttgart UStutt DE Total Budget appr. 2.6 Mio, duration 2.5 years
PROTEST - Contents of Presentation Page 2 Motivation and Scope Concept and Objectives Approach and Work Packages Case Study: Drive Train Outlook
PROTEST - Motivation and Scope Page 3 EU Policy enforces use of renewable Energies Sizes of turbines and sizes of wind farms increase Reliability of turbines is a pre-requisite for economic exploitation of wind energy Statistics say: turbines show 2 to 5 failures per year that require attendance
PROTEST - Motivation and Scope Page 4 Statistics say: turbines show 2 to 5 failures per year that require attendance and electrical components fail more often however: cost and downtime are governed by failures of mechanical systems drive train, pitch and yaw systems, bearings
PROTEST - Concept and Objectives Page 5 Reasons for such failures of mechanical systems as mentioned in studies and expert discussions: lack of knowledge on loads at component level shortcomings in standard load simulation models
PROTEST - Concept and Objectives Page 6 fast turbine growth with little time for development 7.000 kw Rotor Diameter, m 140 120 100 80 60 40 20 Serial production Prototypes 50 kw 300 kw 500 kw 600 kw 1,500 kw 2,500 kw 5,000 kw 0 1980 1985 1990 1995 2000 2005 2010 Year
PROTEST - Concept and Objectives Page 7 What are the answers to the problem? Monitoring cannot solve the problem! CMS and frequent inspections will help detect failures earlier but cannot avoid failures due to unexpected loading Design procedures for mechanical components other than blades and tower need improvement
PROTEST - Concept and Objectives Page 8 Loads at interconnection points of component to turbine structure shall be clearly specified M edge M torsion M flap Global blade loads Ip_1 Ip_2 F r_z Thrust F r_y M yaw Torque M tilt Ip_6 Global rotor loads Ip_9 Ip_8 Ip_3 Ip_4 Ip_5 Ip_7 M t_z F t_z M t_x M t_y F t_x F t_y Global tower loads
PROTEST - Concept and Objectives Page 9 Recommended practices on how to assess the actual loading of the component by prototype/validation testing shall be developed T_in_GB_t W 1.20 1.15 1.10 1.05 1.00 0.95 0.90 0.85 0.80 0.75 0.70 0.65 0.60 0.55 0.50 0:23:00 0:23:10 0:23:20 0:23:30 0:23:40 0:23:50 0:24:00 0:24:10 0:24:20 0:24:30 0:24:40 0:24:50 0 Tage h:m:s % 4.5 T_in_GB T_Geno 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20
PROTEST - Concept and Objectives Page 10 Overall Objective of PROTEST Setting up a methodology that enables standardized specification of design loads for mechanical components s.a. drive train, pitch system and yaw system.
PROTEST - Concept and Objectives Page 11 Guidance on how to derive loads at interconnection points. Guidance for lab testing Laboratory testing Determination of design loads Improvement of component Prototype measurements Guidance communicate results Guidance for validation testing
PROTEST - Approach and Work Packages Page 12 Approach and Work Packages Assessment of common practice State-of-the-art-Report WP1 Questionnaires WP2 & 4 assessment of load cases and design drivers assessment of measurement procedures Find white spots and bottle necks & draft procedures Definition of how to report loads at interconnection points WP3 Prototype measurement definition WP4
PROTEST - Approach and Work Packages Page 13 Application of draft procedures of WP 1-4 in case studies: Case study on drive train loads WP5 SUZLON, HANSEN, DEWI Case study on pitch system loads WP6 ECN, CRES Case study on yaw system loads WP7 ECN, CRES
PROTEST - Case study on drive train loads Page 14 Measurements are carried out by SUZLON/HANSEN/DEWI at a SUZLON S82-1.5MW turbine in India Gearbox of Hansen Transmissions In addition to the "standard" measurement campaign in accordance with IEC 61400-13, the signal list is expanded: additional signals, which are of special relevance for the drive train
PROTEST - Case study on drive train loads Page 15 loads on the main shaft: bending loads torque torque on the high speed shaft rotational speed levels: high speed shaft intermediate speed shaft main shaft rotor position axial displacement of high speed shaft, intermediate speed shaft and low speed shaft
PROTEST - Case study on drive train loads Page 16 displacement of the gearbox in the nacelle temperatures: outdoor ambient air flow (cooler input & output) bearings high speed shaft bearings intermediate speed shaft oil sump oil in cooler & at manifold oil pressures: in front of / behind the mechanical pump at the manifold
PROTEST - Case study on drive train loads Page 17 T_in_GB_t W 1.20 1.15 1.10 1.05 1.00 0.95 0.90 0.85 0.80 0.75 0.70 0.65 0.60 0.55 0.50 0:23:00 0:23:10 0:23:20 0:23:30 0:23:40 0:23:50 0:24:00 0:24:10 0:24:20 0:24:30 0:24:40 0:24:50 0 Tage time series of gearbox input torque h:m:s
PROTEST - Case study on drive train loads Page 18 T_in_GB % 4.4 4.2 4.0 3.8 3.6 3.4 3.2 3.0 2.8 2.6 2.4 2.2 2.0 1.8 1.6 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0.0 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 derivation of torque LDD of gearbox input shaft (LDD = Load Duration Distribution)
PROTEST - Case study on drive train loads Page 19 W 1.20 T_in_GB_t T_Geno_t 1.15 1.10 1.05 1.00 0.95 0.90 0.85 0.80 0.75 0.70 0.65 0.60 0.55 0.50 0:23:00 0:23:10 0:23:20 0:23:30 0:23:40 0:23:50 0:24:00 0:24:10 0:24:20 0:24:30 0:24:40 0:24:50 0 Tage time series - generator shaft torque h:m:s
PROTEST - Case study on drive train loads Page 20 % 4.5 T_in_GB T_Geno 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 derivation of torque LDD of generator shaft torque (LDD = Load Duration Distribution)
PROTEST - Case study on drive train loads Page 21 T_in_GB_t T_Geno_t T_out_GB_tx W 1.20 1.15 1.10 1.05 1.00 0.95 0.90 0.85 0.80 0.75 0.70 0.65 0.60 0.55 0.50 0:23:00 0:23:10 0:23:20 0:23:30 0:23:40 0:23:50 0:24:00 0:24:10 0:24:20 0:24:30 0:24:40 0:24:50 0 Tage Perturbed shaft torque - green signal h:m:s
PROTEST - Case study on drive train loads Page 22 T_in_GB T_Geno T_out_GBx % 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 derivation of torque LDD of perturbed shaft torque (LDD = Load Duration Distribution)
PROTEST - Case study on drive train loads Page 23 + + % 4.4 T_in_GB 4.2 4.0 1 3.8 3.6 3.4 3.2 3.0 2.8 2.6 2.4 2.2 T_in_GB 2.0 % 1.8 4.4 1.6 4.2 1.4 4.0 1.2 3.8 2 1.0 3.6 0.8 3.4 0.6 3.2 0.4 3.0 0.2 2.8 0.0 2.6 0.502.4 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 2.2 2.0 % 1.8 1.6T_in_GB 1.4 1.2 4.4 1.0 4.2 0.8 4.0 0.6 3.8 0.4 3.6 0.2 3.4 n 0.0 3.2 3.00.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 2.8 2.6 2.4 2.2 2.0 1.8 1.6 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0.0 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 = % 4.0 3.8 3.6 3.4 3.2 3.0 2.8 2.6 2.4 2.2 2.0 1.8 1.6 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0.0 Trot_c_TaL 0 10 20 30 40 50 60 70 80 90 100 Service life LDD = weighted accumulation of individual 10-min-LDD s Klassen
PROTEST - Case study on drive train loads Page 24 C 68.0 66.0 64.0 62.0 60.0 58.0 56.0 54.0 52.0 50.0 48.0 46.0 44.0 42.0 40.0 38.0 36.0 t_in_gear t_out_gear_in_bearing t_out_gear_out_bearing P_WT 600.0 610.0 620.0 630.0 640.0 650.0 660.0 670.0 680.0 690.0 temperatures, here: 10-min-statistics 10^3 % 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0
PROTEST - Case study on drive train loads Page 25 µm 200 150 100 50 0-50 -100 µm 100 dp_mean dp_max dp_min dp_stdev 80 60 40 20 0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 displacements, here: 10-min-statistics %
PROTEST - Case study on drive train loads Page 26 Multi-body simulations are carried out by University of Stuttgart / SUZLON to establish global loads and loads at interconnecting points comparison of design loads to measurements Feed-back on procedures as defined under WP3 and WP4
PROTEST - Case study on drive train loads Page 27 Case study ongoing improvement of setup next campaign planned for December 2008
PROTEST - Thank You Page 28 Thank you for your attention!