Quantifying the value of reducing Transient Loads, utilizing a cost-based FMEA approach

1. Proac&ve Turbine Damage Reduc&on
-Quan&fying the value of reducing Transient Loads,
u&lizing a life cost-based FMEA approach
Webinar Series

2. #WindWebinar
q This webinar will be available afterwards at
www.windpowerengineering.com & email
q Q&A at the end of the presentation
q Hashtag for this webinar: #WindWebinar
Before We Start

3. #WindWebinar
Michelle Froese
Senior Editor - Moderator
Windpower Engineering
& Development
Dustin Sadler
Principal Engineer
AeroTorque Corp.
Doug Herr
VP of Sales and Marketing
AeroTorque Corp.
Proactive Turbine Damage Reduction
Meet your Presenters…

4. #WindWebinar
1. What is a Transient Torsional Event?
2. How do you mi:gate damaging TTEs?
3. How does this affect turbine reliability?
4. What is the value to your Cost of Energy?

5. #WindWebinar
• The data shows a 50-70%
reduc:on in the worst
loads from transient
torsional events
• The value of those
reduc:ons to your turbines
and your boHom line!

6. #WindWebinar
Taming Torsional Loads in the World’s Most Extreme Machines for 37 Years.

7. #WindWebinar
This is your turbine
making money!

8. #WindWebinar
Example:
Braking Procedure
during a Hard Stop
Normal Opera&on
Stopping Protocol
Triggered
Combined Aero- and Caliper
Disc Braking
Torque Reversal
when ShaM Stops
The final torque reversal occurs
when the shaW stops rota:ng!

9. #WindWebinar
Any control system reac:on requiring rapid pitching
and/or strong mechanical braking.

10. #WindWebinar
• E-stops are not the only hard
stops.
• E-stops are not the only damaging
type of stopping events.

11. #WindWebinar
Winds also ini:ate
transient loads!

12. #WindWebinar

13. #WindWebinar
“Reverse Torsional Damper”

14. #WindWebinar
1.6 MW Turbine
Ini:al Slip Event
Removes Torsional
Energy
1
50-75% Reduc:on
Torsional Oscilla&ons
2
75-100% Reduc:on
Reverse Loading
3

15. #WindWebinar
These loads
are not
unique to
any OEM’s
turbines!

16. #WindWebinar
Hard Stop in a 1.65 MW turbine
Ini:al Slip Event
Removes Torsional Energy
1
75-100% Reduc:on
Reverse Loading
3
50-75% Reduc:on
Torsional Oscilla&ons
2
1.65 MW Turbine

17. #WindWebinar
Torsional Oscilla&ons and Vibra&on
* Shockloads Through the Turbine *
2
Torque Reversal & Impact Loading
* Torsional Loading w/o Rota:on *
3
Slipping begins
* Limits Max Torque*
1
1.6 MW Turbine

18. #WindWebinar
During Torque Reversals, load zones shiW 180⁰.

19. #WindWebinar
Calcula:ons show 25+ year life.
Why are
bearings
failing
sooner?
90% Crack Genera&on
10% Crack Propaga&on
Crack Genera&on Crack Propaga&on Failure

20. #WindWebinar
MORE than the Gearbox:
What else is affected by transient events?
• Main Bearings
• Generator Bearings
• Generator Rotor
Windings
• High Speed Coupling
• Main ShaM to Hub Bolts
• Rotor Blades
• Blade to Pitch Bearing
Bolts
• Electronics/ Electrical
Systems
• Bedplate

21. #WindWebinar
Recent comple:on of the first,
independent, non-OEM
Failure Modes and Effects Analysis
(FMEA)
of the en:re Turbine.
White paper and FMEA available.

22. #WindWebinar
Sco^ Eatherton, President, Wind Driven LLC.
Emil Moroz, President, EM Energy LLC
Dave Heidenreich, P.E., Founder and Re&red Chief Engineer of PT Tech, Inc.
Dus&n Sadler, Principal Engineer, AeroTorque Corpora&on

23. #WindWebinar

24. #WindWebinar

25. #WindWebinar
High Speed Shaft
Assembly
High Speed
Intermediate
Shaft
Assembly
Low Speed
Shaft
Assembly
Low Speed
Intermediate
Shaft
Assembly
Images courtesy of Olympus-IMS and NREL

26. #WindWebinar
Internal
Support
(hrs)
Aver
Labor
($/h
Total internal cost
restore compone
function
Projected
Mean Time
Between
Failures/
Repairs
(yrs)
Component
Expected
Useful
Turbine Life
(yrs)
Total external
cost to
restore
component
function

27. #WindWebinar

28. #WindWebinar

29. #WindWebinar

30. #WindWebinar
• Actual Costs
• Actual Repairs
• Actual KW-hr
• Actual Capacity
Factors

31. #WindWebinar
Internal
Support
(Man hrs)
Average
Labor Cost
($/hr)
Projected
Mean Time
Between
Failures/
Repairs
(yrs)
Mean Crane
Cost
($/event)
Estimated
Downtime
(days/event)
Estimated
Cost of
Downtime
($/event)
Calculated
Annualized
Value for
Repairs or
Replacements
Component
Expected
Useful
Turbine Life
(yrs)
Total external
cost to
restore
component
function
Total internal cost to
restore component
function
Projected
Failures in
Life of
Turbine
(yrs)
Credibility of Evidence
that links TTEs to
failure mode
Contribution
Towards Failure
(percentage)
Estimated Life
Extension
(percentage)
Estimated New
Time Between
Failures
(yrs)
Failure Modes that can be mitigated by a reduction in Transient Torque Events
(TTEs)
Projected Life Improvement for a WindTC in Mitigating TTE DamageProjected
Annualized Value
attributed to the
WindTC
Assuming No
Downtime (no
soft costs)

32. #WindWebinar
Over $11,000 annual value of the reduc:on in loads to
Gearbox Components alone, not coun:ng lost produc:on
Gearbox High Speed
Shaft Assembly
(HSS)
20 5 $5,264 Bearing Fatigue - Surface & Subsurface - Macropitting $3,458.89 $2,102.52
Gearbox High Speed
Intermediate Shaft
Assembly (HSIS)
25 10 $6,095 Bearing Fatigue - Surface & Subsurface - Micropitting $3,054.85 $2,232.03
Gearbox Low Speed
Intermediate Shaft
Assembly (LSIS)
25 15 $11,770 Bearing Fatigue - Surface & Subsurface - Micropitting $2,391.93 $2,139.11
Gearbox Low Speed
Shaft Assembly (LSS)
25 25 $10,062 Bearing Fatigue - Surface & Subsurface - Micropitting $4,879.69 $4,633.98
$13,785 $11,108
Assuming No
Downtime (no
soft costs)
GEARBOX COMPONENTS
Component
Expected
Useful
Turbine Life
(yrs)
Projected Mean
Time Between
Failures/ Repairs
(yrs)
Calculated
Annualized
Cost for
Repairs or
Replacements
Failure Modes that can be mitigated by a reduction in Transient Torque
Events (TTEs)
Projected
Annualized Value
attributed to the
WindTC
$13,785 $11,108

33. #WindWebinar
Annualized “hard” value:
Over $12,600 per
year installed
With lost opportunity
“soW costs”, such as lost
produc:on, the value
grows to $15,000
Component
Expected Useful Turbine Life
(yrs)
Projected Mean Time
Between Failures/ Repairs
(yrs)
Calculated Annualized Cost
for Repairs or Replacements
Projected
Annualized Value
aHributed to the
WindTC
Projected
Annualized Value
without Down:me
GEARBOX COMPONENTS
Gearbox High Speed ShaW Assembly
(HSS)
20 5 $5,264 $3,458.89 $2,102.52
Gearbox High Speed Intermediate
ShaW Assembly (HSIS)
20 10 $5,748 $3,054.85 $2,232.03
Gearbox Low Speed Intermediate
ShaW Assembly (LSIS)
20 10 $5,748 $2,391.93 $2,139.11
Gearbox Low Speed ShaW Assembly
(LSS)
20 15 $9,766 $4,879.69 $4,633.98
TOTAL ANNUAL VALUE TO GEARBOX $13,785 $11,108
OTHER DRIVETRAIN COMPONENTS
Main ShaW Bearings 20 15 $15,272 $1,189.24 $1,108.86
Generator Bearings 20 8 $1,626 $28.99 $24.06
Generator Rotor Windings 20 10 $14,628 $91.63 $81.93
High Speed Coupling 20 15 $841 $282.66 $233.09
Rotor Blade Repair 20 8 $3,111 $35.10 $29.90
Main ShaW to Hub Bolts 20 20 $8,651 $15.56 $15.36
Blade to Pitch Bearings and Bolts 20 20 $5,068 $16.68 $15.83
TOTAL ANNUAL VALUE TO OTHER DRIVETRAIN COMPONENTS $1,660 $1,509
OTHER TURBINE COMPONENTS
Tower Repairs / Tower Bolts /
Anchor Bolts
20 20 $1,484 $0.15 $0.13
Electronics / Electrical Systems 20 2 $2,306 $3.45 $1.80
Power Cables 20 20 $2,838 $0.00 $0.00
Bedplate 20 25 $7,818 $14.06 $12.57
TOTAL ANNUAL VALUE TO OTHER TURBINE COMPONENTS $18 $15
TOTAL ANNUAL VALUE TO ENTIRE TURBINE $15,462.88 $12,631.17

34. #WindWebinar
Current Annual Revenue/Turbine
If we can just increase availability 1%...
Addi:onal Revenue = $3,700/turbine/year
$0.08 (Rate) X 32% (Capacity) X 97% (Availability) X 365 days X 24 hrs X 1.65 MW = $359K

35. #WindWebinar
Down:me is more expensive
than most people think!
Down:me costs you $1,000 a day/turbine/
average
Down:me during produc:on
Costs you $3,000/day!

36. #WindWebinar
• Transient loading is going on in your turbines,
likely more oWen than expected
• These loads/events can cause long-term
damage to your turbines

37. #WindWebinar
• There is a solu:on that addresses many of the
effects of these loads by reducing the energy
stored in the system
• This solu:on shows a return on investment of
over $15,000/year, giving a pay back of less
than a year

38. #WindWebinar
1. Review White Paper & FMEA – this will be
sent to all webinar aHendees.
2. Contact AeroTorque for your customized
ROI for your fleet and failure modes.
3. Set up a mee:ng – Your site or ours.

39. #WindWebinar
Michelle Froese
Senior Editor - Moderator
Windpower Engineering
& Development
mfroese@wtwhmedia.com
@Windpower_Eng Dustin Sadler
Principal Engineer
AeroTorque Corp.
dsadler@aerotorque.com
@AeroTorque
Doug Herr
VP of Sales and Marketing
AeroTorque Corp.
dherr@aerotorque.com
@AeroTorque
Proactive Turbine Damage Reduction
Questions?

40. #WindWebinar
Thank You
q This webinar will be available at
www.windpowerengineering.com & email
q Tweet with hashtag #WindWebinar
q Connect with Windpower Engineering & Development
q Discuss this on EngineeringExchange.com