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Reliability of GE’s 1.5MW Turbine
A Component View
John T. MurphyProduct Service and Warranty
GE Wind Energy
June 17, 2009
2 /
GE /
Wind Services – GE Perspective
GE differentiation
> Resources to scale
> Fleet understanding
> Technology
Scale to 20% → managing large systems
> Organization
> Processes
> Systems and Metrics
Cumbersome at 1000 unitsEffective at 10,000Essential technology at 100,000
g imagination at work
3 /
GE /
Top Level Metrics Drive Reliability Focus
turbine
Avail
FW21
Relia
FW21
fault
rate
DT/Fault
[hrs]
Froidchapelle 2 91.1 91.9 3 5.0
Froidchapelle 7 98.7 98.7 6 0.4
Froidchapelle 8 100 100 1 0.0
Kleisthoehe II 8 96.1 98.4 0 0.0
Kleisthoehe II 9 98.3 99.8 1 2.9
Wilhelmshaven 2.5xl DEWI 98.8 (95.7) 100 0 0.0
FLEET 97.2 98.1 1.8 3.1
09FW21 Availability Review
0.0
6.0
12.0
18.0
24.0
30.0
36.0
42.0
48.0
54.0
60.0
0.0 2.5 5.0 7.5 10.0 12.5
last 4 weeks - faults/unit/week
last
4 w
eeks - downtim
e p
er fa
ult [hrs
]
Mandate:“The best-performing fleet in the world.”
4 /
GE /
Fleet and Services Growth
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
Sep-02 Jan-04 May-05 Oct-06 Feb-08 Jul-09 Nov-10
Inst
alled B
ase
0
20
40
60
80
100
120
PAC/M
onth
5 /
GE /
0
10
20
30
40
50
60
Pum
p
Low O
il Lev
elRi
ng G
ear
Main
Bear
ing
HS P
inion
Fittin
gs/S
enso
rsCo
oler
HS G
ear
LS G
ear
Plan
et G
earSp
litBr
eath
erHo
using
IM Pinion
Low O
il Pre
ssur
e
Slip R
ing
TubeFil
ter
HS B
earin
gsIM
Gea
rOi
l Tem
pSu
n Pinion
Carri
er
Carri
er B
earin
gsLS
Bea
rings
LS Pinion
Plan
et B
earin
gs
Serv
ice Inquiries
A
B
C
D
E
Gearbox Issue Breakdown
Multiple suppliers – insight to entitlement
6 /
GE /
Site B vs. Fleet – Gearbox Low Oil Faulting
EM51 Trips by Supplier - FW43-52 - 2008
0%
20%
40%
60%
80%
100%
A B C D E
Site B
Fleet
GE Fleet knowledge informs corrective actions for site issues
7 /
GE /
Supplier A High-Speed Bearing Failure
Failure of HS shaft tapered rollerRCA: root cause fit tolerance, housing detailIdentified LAT, monitor, replace as requiredWeibull would have predicted >150 failures11 total incidents, all repaired up tower
’07 – 1.7, 1300 hrs
8 /
GE /
Supplier B Sun Pinion Failures
FailurePictures
WeibullPictures
Fracture of sun pinion gear teethRCA with supplierMajority associated with 1 meltIdentify affected population, monitorNo additional failures since ‘08GE supplier audit, process improvementsSupplier proactively tightening specifications
’08 – 1.0, 4.4M hrs
9 /
GE /
Supplier C LS Gear Failure
Fracture of 1 or more LS gear teethFailure not always obvious
Failure times distortedSite concentration
2/3 of all failures at only 2 sitesRCA needs to accommodate operator
Time, (t)
Unreliability, F(t)
100.000 100000.0001000.000 10000.0000.100
0.500
1.000
5.000
10.000
50.000
90.000
99.000
0.100
’09 – 2.1, 82k hrs
A
C
E
F
G
B
D
Site Breakdown
10 /
GE /
Site A vs. Fleet – Gearbox Replacement
Characteristic Life by Supplier
0
50,000
100,000
150,000
200,000
250,000
A B All
Supplier
Life (h
rs)
Fleet
Site A
Fleet big picture vs. particular site or customer
11 /
GE /
Gearbox Replacement Rate
Generational improvement, SLE’s better than S’sReplacement rate for both improving
0.0
0.5
1.0
1.5
2.0
2.5
3.0
2001
Q1
2001
Q3
2002
Q1
2002
Q3
2003
Q1
2003
Q3
2004
Q1
2004
Q3
2005
Q1
2005
Q3
2006
Q1
2006
Q3
2007
Q1
2007
Q3
2008
Q1
2008
Q3
2009
Q1
Repla
cem
ents
/Qrtr (%
Inst
alled B
ase
)
1.5S
1.5SLEOld Technology
New Technology
12 /
GE /
Weibull Characteristic Life
1.E+04
1.E+05
1.E+06
1.E+07
Nov-07 Feb-08 Jun-08 Sep-08 Dec-08 Mar-09 Jul-09
Eta
(hrs
)A
B
C
D
More consistent results among suppliersRelative supplier performance shifts over time
13 /
GE /
Material Cleanliness
Fatigue fracture of gears
> Frequently able to trace to actual inclusion, type and size
> Several suppliers, steel producers tightening requirements
GE finalizing gear specification
> In line with supplier/producer trend
> Reference more common specs, American and European
14 /
GE /
HALT Testing
Introduced as requirement by GE in 2004-5 time period
> Standardize test and evaluation among suppliers
> Enable more rapid endurance testing of gearbox
> Reproduce observed field failure modes in controlled environment
> Need to continue to evaluate results and requirements in context of field observations
15 /
GE /
Inspection and Characterization
Phased Array UT Inspection of Ring Gear
> Extension of GE Energy process for steam turbine rotors
> Instrumention available from GE Inspection Technologies
> Enables examination of entire ring gear from outer surface
16 /
GE /
CBM
Vibration and particle monitoring
Reduce unplanned downtime
Coordinate with planned
maintenance
Reduction of collateral damage
17 /
GE /
Thank you!
g imagination at work
