Bently Nevada Wind CMS Offerings

Oil & Gas Power Generation

• Thermal• CCPP• Co-Gen• Hydro• Wind

• LNG• Ethylene• Refining• Fertilizers• PTA

Who is Bently Nevada?

Switch/Hub

Rotating Machines

Online - Continuousmonitoring & protection

3500 & TDI

Online – Periodic(scanning) monitoring

Wired Wireless

Essential Assets• Fans

• Pumps

• Blowers

• Etc…

SCOUT 100

BOP Assets• Vibration

• Portable Devices

• Lube Oil

• Thermography

• MCA, etc…

Offline – Periodic walk-around monitoring

Critical Assets• Gas Turbines

• Steam Turbines

• Compressors

• Main line Pumps

Bently Nevada – Online Condition Monitoring

Why Plant Asset Optimization?

Optimization of plant asset performance and reliability is essential to meeting the challenge of increased production at lower costs - a situation

faced by many companies in a world of increased competition

Improved:• Safety, environmental compliance• Reliability, availability• Throughput, quality• Planning and scheduling• Maintenance efficiency• Spare parts inventory

Reduced:• Downtime• Energy consumption• Maintenance costs Plant Asset Optimization

Wind Farm Operators strive to optimize their maintenance resources by minimizing down-tower repairs & making sure parts are on hand Graphic from EPRI Paper – Condition Monitoring of Wind Turbines

What are the business challenges?

Benefits of Early Detection

• Limit downtower repairs

• Eliminate expedited crane charges

• Crane bundling to minimize mobilization and demobilization charges

• Minimize downtime and optimize planning for low wind repairs

“25%-30% of the overall operation and maintenance costs at a wind farm will be associated with the gearbox alone.”*

*EPRI Paper – Condition Monitoring of Wind Turbines

Why Drive Train CMS?

Failure Rates, Costs, and CMS Value

Component Failure Rate Total Cost Detection Rate (%)

Savings From CMS

Total Savings

Gearbox 3% $255,240 50% $80,000 $1,200

GearboxRefurbishment

38% $200,240 50% $80,000 $15,200

Generator 5% $146,280 80% $30,000 $1,200

Main Bearing 18% $135,240 40% $20,000 $1,440

Generator Refurbishment

10% $113,280 80% $30,000 $2,400

Gearbox Stage Replacement

35% $40,760 50% $10,000 $1,750

Average Savings from CMS: $23,190 per turbine

Bently Nevada Wind CMS Offerings

Entered Market with DSM Solution

~ 25 Units installed

2004 2006 2008 2009 2012 +

Refine Wind solution: Independent

processor/Scalable ADAPT. Wind Released

Continuous Product

Enhancements

DSM Solution ~ 25 Units installed

TurningPoint ~ 2000 Units installed

SmartSignal ~ 150 Units installed

ADAPT.Wind ~ 3000 Units installed

ADAPT.Wind - Standard Option for GE New Units & Included in LTSA

Condition Monitoring System

Drivetrain TransducersUp-Tower

SoftwareMonitorUp-Tower

Network Friendly Architecture

Monitors communicate with the farm server via the SCADA Network.

Utility Transmission System

SCADA Server Local ADAPT Server

Firewall

SCADA Network

Remote Monitoring Center

WAN

Expandability

Farm Server

• Bently Nevada Data Services• ADAPT.wind Farm Client or Ascent

WTG1 Monitor

WTG2 Monitor

WTG199 Monitor

WTG200 Monitor

One farm server can accommodate up to 200 Wind Turbine Generator (WTG) monitors.

SCADA Network

WTG3 through WTG198

Ethernet Switch

Transducer Locations

Ring Gear

Sun Gear

Planet Gear

Rotor Hub

HSS

HSIS

LSIS

Generator

Gearbox

HSS Speed

LSS Speed

LSS

Main Bearing

Intermediate Stage

Planetary Stage

High Speed Stage

Generator Bearings

6 accelerometers

2 speed sensors

Powerful Calculation Engine

• Calculation engine embedded inside the monitor• Patented Algorithms – DEI & SER• Up to 200 trendable variables

• Component specific variables for the main bearing, generator, and gearbox

• Available as input into SmartSignal Predictive Analytics• Data is stored, trended, and alarmed.

Powerful Diagnostics

Sensor Health– Transducer Bias Voltage

Broadband– Direct Peak Amplitude– Direct RMS Amplitude– Crest Factor– Kurtosis– Cumulative Impulse (CI)

Spectral Bands– Orders-Based Amplitude– Dynamic Energy Index (DEI)– Enveloped (demodulated)

Bearing Fault Frequencies– Gearmesh Frequencies– Gearbox Fault Frequencies

• Planet Fault (3X LSS), Ring Fault, Sun Fault, etc.

These measurements are processed by the 3701/60 monitor.

ADAPT.Wind calculated variables

•Advanced Techniques• Planetary Impulse Detection (particle trend)

Cumulative Impulse CountCumulative Impulse RateCumulative Impulse Magnitude

• DEI Dynamic Energy Index…Specifically designed for variable speed machines.

• Kurtosis

4.538 4.54 4.542 4.544 4.546 4.548 4.55 4.5520

1

2

3

4

5

6

7

8

Time (s)

g

SlavePlanetaryRotor16Apr10second1; corner = 0.1 Hz; order 2; 13 events for DI = 66 GE CONFIDENTIAL

Planetary debris passage detection by cumulative impulse calculations

AmplitudeResets

AdaptiveThreshold(12 x LP signal)

Low-pass filtered signal (red)

DecayEnvelope

Final Maximum For Event (red dot)

RectifiedSignal

EventTerminationEvent

Start

DefaultThreshold4 g

Dynamic Energy Index (DEI) Bands - Definition

Spectral Energy is summed within Discrete Frequency Bands shown here, where the Bands correspond to gearbox components.DEI Variables are normalized by Torque

Variable Frequency Range Description

DEI Bearing 0 – 25 Hz L.S. shaft bearings, Planet bearings, all rotor-related frequencies

DEI Planetary 28 – 130 Hz Planetary Gear Mesh Frequencies

DEI Intermediate 145 – 570 Hz Intermediate gear mesh frequencies

DEI High 590 – 3300 Hz High Speed gear mesh frequencies

DEI Structural 4000 – 10000 Hz Covers structural resonant frequencies which are excited by mechanical impacts

DEI Bands

New Healthy Gearbox

Same Gearbox After HALT damage

Damaged Gearbox

NewGB

DamagedGB Ratio

DEI Bearing 3.95E-06 4.75E-04 120.1DEI Planetary 4.39E-04 1.00E-02 22.9DEI Intermediate 5.37E-04 3.36E-02 62.6DEI High Speed 1.21E-02 4.47E-01 37.1DEI Structural 3.60E-02 5.63E+00 156.4

DEI Test values:

DEI Bands – Overlaid on actual Frequency Spectrums comparing the gearbox vibration signature of the same gearbox at the beginning and end of a HALT test.

Kurtosis

•Variance (standard deviation squared) involves the square of differences between data and the mean•Variance is the 2nd moment•Skew is the 3rd moment

•Kurtosis is the 4th moment. It puts more emphasis on the tails of the distribution

•Spikier waveforms have higher Kurtosis

Planetary Sun Gear Failure

Background>Vibration increased in planetary stage>ADAPT showed high overall vibration and defect on

sun gear

Benefits …

>Two weeks advanced notice>Confirmed crane mobilization required>Confirmed gearbox replacement required

Generator Drive End Bearing EDM

Damage

Corrosion

Spectrum Waterfall –shows signs of bearing EDM (electrical discharge machining) progressing rapidly.

Bearing Inner Race and Sidebands

Spectrum Detail – shows repeating harmonic peaks of ORBP (Outer Race Ball Pass) frequency, a classic sign of EDM.

Harmonics with Sidebands

Generator Drive End Bearing EDM

• Ensures proper generator slip-ring operation

• Uptower repair

• Early detection of EDM allows corrective action to be taken prior to significant bearing damage occurring

Cost Saving Examples – Bearing Cracks

• Reduced secondary damage

• Uptower repair

• Trending allows for maintenance during maintenance or low winds

Broken HSIS Pinion Tooth (Sideband Energy Ratio)

SER = 1.1SER = 3.9 SER = 5.6

Questions?