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Condition Monitoring of the Drive Train Myths
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Bachmann electronic GmbH
CONDITION MONITORING OF THE DRIVE TRAIN MYTHS
end of warranty and permanent installations
- David Clark
Bachmann electronic GmbH
WHAT WILL FAIL? AVERAGE SIZE 1.5-2.5MW
Bachmann electronic GmbH
WHAT WILL FAIL AT EACH SENSOR LOCATION?
Bachmann electronic GmbH
TURBINE GEARBOX COMMON INSPECTION TECHNIQUESComponent detection percentages on a typical gearbox
VISUAL INSPECTION BORESCOPE INSPECTION VIBRATION ANALYSIS
High Speed Pinion 50% 50% 100% Intermediate Wheel & Pinion 100% n/a† 100% Low-Speed Wheel 100% n/a† 100% Sun Gear No 30%§ 100% Planetary Gears (3) 10% 30%§ 100% Ring Gear 20% 30% 100% High Speed Bearings (3) No 100% 100% Intermediate Bearings (2-3) No 50%‡ 100% Low Speed Bearings (2) No 50%‡ 100% Planetary Carrier Bearings (2) No 30%§ 100% Planetary Gear Bearings (6 drCRB) No 30%§ 100%
† Clearly visible during visual inspection by removal of inspection cover ‡ Depends upon gearbox make/model, oil level and bearing configuration § Requires several rotations of rotor and to inspect 100%, adding several hours to inspection By Don Roberts and David Clark
Bachmann electronic GmbH
DIFFERENT TYPES OF VIBRATION UNITS- Velocity, acceleration, displacement, demodulated/enveloped, time waveform, overall.
TIME WAVEFORM VIBRATION SPECTRUM
FFT
Bachmann electronic GmbH
CONDITION MONITORING MYTHS
. Need lots of data, lots of measurements, with a baseline
. Too difficult to understand the data
. Not cost justified
. Cannot detect planet section issues
…..All condition monitoring is the same
Bachmann electronic GmbH
FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz30/04/2004 2:14:30 p.m.
Hz0 200 400 600 800 1,000 1,20
g rm
s
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7O/All 0.991 g rms
30/04/2004 2:14:30 p.m. O/All 0.991 g rms <set RPM>
FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz7/07/2004 5:04:47 p.m.
Hz0 200 400 600 800 1,000 1,20
g rm
s
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7O/All 0.468 g rms
7/07/2004 5:04:47 p.m. O/All 0.468 g rms <set RPM>
RING GEAR
Bachmann electronic GmbH
FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz7/07/2004 5:04:47 p.m.
Hz0 200 400 600 800 1,000 1,20
g rm
s
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7O/All 0.468 g rms
7/07/2004 5:04:47 p.m. O/All 0.468 g rms <set RPM>
FFT 1-30 - FFT 1 - Not specified - Acc Freq 1200 Hz30/04/2004 2:14:30 p.m.
Hz0 200 400 600 800 1,000 1,20
g rm
s
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7O/All 0.991 g rms
30/04/2004 2:14:30 p.m. O/All 0.991 g rms <set RPM>
Bachmann electronic GmbH
HIGH SPEED SECTION (HSS)
Bachmann electronic GmbH
HIGH SPEED SECTION (HSS)
secs0 1 2 3 4 5 6 7 8
g
-0.8
-0.6
-0.4-0.4
-0.2
0
0.2
0.4
0.6
O/All 0.062 g RMS
Machine Note (3/8/2010 11:09:42 AM)Changed to High RPM recording 3-8-10 RK
T03 Gbx HighSpeed Horizontal [Tach] Acc Wfm 8000 ms 6/23/2011 8:03:10 AM O/All 0.062 g RMS 1802.787 RPMT04 Gbx HighSpeed Horizontal [Tach] Acc Wfm 8000 ms 3/14/2011 3:18:04 PM O/All 0.23 g RMS 1829.291 RPM
Bachmann electronic GmbH
PLANETARY SECTION
secs0 10 20 30 40 50 60
g
-1
0
1
2
3
4O/All 0.312 g RMS
Machine Note (3/8/2010 11:09:31 AM)Changed to High RPM recording 3-8-10 RK
T04 Gbx Planetary Horizontal [Tach] Acc Wfm 64000 ms 3/14/2011 3:10:40 PM O/All 0.312 g RMS 20.484 RPMT03 Gbx Planetary Horizontal [Tach] Acc Wfm 64000 ms 6/23/2011 8:10:43 AM O/All 0.035 g RMS 20.297 RPM
Bachmann electronic GmbH
CONDITION MONITORING MYTHS
. Need lots of data, lots of measurements,with a baseline
. Too difficult to understand the data
. Not cost justified
. Cannot detect planet section issues
…..All condition monitoring is the same
Bachmann electronic GmbHWind FACTS V2.2
CPM0 20,000 40,000 60,000 80,000 100,000 120,000
g RM
S
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
0.2
0.003 g37.687 orders48773.234 CPMCursor A:O/All 0.243 g RMS
Turbine 18 HS Gbx Bearing Vertical [Tach] Demod Spec (2-10kHz) 120000 CPM 8/17/2009 8:09:43 AM O/All 0.243 g RMSTurbine 19 high Speed Vertical Demod Spec (2-10kHz) 120000 CPM 8/17/2009 8:09:24 AM O/All 0.03 g RMS
QJ3
28 B
PFI
QJ3
28 B
PFI
QJ3
28 B
PFI
QJ3
28 B
PFI
HIGH SPEED SHAFT (HSS) $300,000 spectrum
Bachmann electronic GmbH
GENERATOR BEARING, $95k spectrum
Bachmann electronic GmbH
EPRI REPORT COST JUSTIFICATIONS
Bachmann electronic GmbH
CONDITION MONITORING MYTHS
. Need lots of data, lots of measurements, with a baseline
. Too difficult to understand the data
. Not cost justified
. Cannot detect planet section issues
…..All condition monitoring is the same
Bachmann electronic GmbH
PLANET GEAR BEARING
Bachmann electronic GmbH
PLANET GEAR
Bachmann electronic GmbH
PLANET SECTION
Bachmann electronic GmbH
PLANET GEAR
Bachmann electronic GmbH
CONDITION MONITORING MYTHS
. Need lots of data, lots of measurements,with a baseline
. Too difficult to understand the data
. Not cost justified
. Cannot detect planet section issues
…..All condition monitoring is the same
Bachmann electronic GmbH
+/- 20% ACCURACY
Bachmann electronic GmbH
60 RPM +
12 RPM +
Bachmann electronic GmbH
+/- 20% ACCURACY
BOTH ARE CURRENTLY BEING INSTALLED WITH OEM CONDITION MONITORING SYSTEMS
WRONG SENSORS
+/- 20% ACCURACYUSING HIGH SPEED SENSOR IN LOW SPEED LOCATION
Bachmann electronic GmbH
CONDITION MONITORING MYTHS
. Need lots of data, lots of measurements,with a baseline
. Too difficult to understand the data
. Not cost justified
. Cannot detect planet section issues
…..All condition monitoring is the same
Bachmann electronic GmbH
TRENDING EXAMPLES
Bachmann electronic GmbH
6/11 warning
8/26Replacement
of the gearbox1/8
alarm
planetary stage
Bachmann electronic GmbH
2/3 warning
5/13Replacement of the bearing
2/17 alarm
HSS bearing
Bachmann electronic GmbH
DAVID CLARKd.clark@bachmann.info
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