Bently Nevada Wind CMS Offerings

1. Bently Nevada Wind CMS Offerings

2. Oil & Gas Power Generation
• Thermal
• CCPP
• Co-Gen
• Hydro
• Wind
• LNG
• Ethylene
• Refining
• Fertilizers
• PTA
Who is Bently Nevada?

3. Switch/Hub
Rotating Machines
Online - Continuous
monitoring & 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

4. 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

5. 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?

6. 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

7. “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?

8. 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
Gearbox
Refurbishment
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

9. 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

10. Condition Monitoring System
Drivetrain Transducers
Up-Tower
SoftwareMonitor
Up-Tower

11. 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

12. 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

13. 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

14. 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.

15. 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.

16. ADAPT.Wind calculated variables
•Advanced Techniques
• Planetary Impulse Detection (particle trend)
Cumulative Impulse Count
Cumulative Impulse Rate
Cumulative Impulse Magnitude
• DEI Dynamic Energy Index…
Specifically designed for variable speed machines.
• Kurtosis

17. 4.538 4.54 4.542 4.544 4.546 4.548 4.55 4.552
0
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
Amplitude
Resets
Adaptive
Threshold
(12 x LP signal)
Low-pass filtered signal (red)
Decay
Envelope
Final Maximum For Event (red dot)
Rectified
Signal
Event
TerminationEvent
Start
Default
Threshold
4 g

18. 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

19. DEI Bands
New
Healthy
Gearbox
Same Gearbox After
HALT damage
Damaged
Gearbox
New
GB
Damaged
GB Ratio
DEI Bearing 3.95E-06 4.75E-04 120.1
DEI Planetary 4.39E-04 1.00E-02 22.9
DEI Intermediate 5.37E-04 3.36E-02 62.6
DEI High Speed 1.21E-02 4.47E-01 37.1
DEI 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.

20. 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

21. 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

22. 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

23. 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

24. Cost Saving Examples – Bearing Cracks
• Reduced secondary damage
• Uptower repair
• Trending allows for maintenance during
maintenance or low winds

25. Broken HSIS Pinion Tooth (Sideband Energy Ratio)
SER = 1.1
SER = 3.9 SER = 5.6

26. Questions?