wind drivetrain bearing reliability
DESCRIPTION
ÂTRANSCRIPT
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Wind Drivetrain Bearing Reliability
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Before We Start This webinar will be available at
www.windpowerengineering.com & email
Q&A at the end of the presentation
Hashtag for this webinar: #WindWebinar
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Moderator Presenter
Paul DvorakWindpower
Engineering & Development
Rick BrooksThe Timken Company
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Wind Drivetrain Bearing Reliability
Presented by The Timken Co.Richard Brooks, Mgr. Wind North America
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WIND TURBINE DRIVETRAIN - COMMON BEARING DAMAGE
Generator Bearings
Gearbox High Speed Bearings
Gearbox Planet Bearings
Main Shaft Bearings
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FINANCIAL IMPACT - WIND DRIVETRAIN BEARING DAMAGE
Low High$0
$500,000TOTAL REPAIR
COST
Frequency of Occurrence
Generator BearingsGearbox High Speed Bearings
Gearbox Planet Bearings
Main Shaft Bearings
$$$
$
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UP TOWER VS. DOWN TOWER REPAIRSUp Tower Down Tower
Crane Costs +++ ---Self Perform ++ -Clean Environment - ++Load Test --- ++Per Event Cost ~$10-$20k ~$250k-$500k
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Two TS
TDI and CRB Ultrawind
Two SRBs
Single SRB
WIND TURBINE MAIN SHAFT MOUNTS
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Hub Weight
Wind Thrust
Torque
Overturning Moments
Spherical Roller (SRB)
Main Bearing
MAIN SHAFT APPLICATION REVIEW-3 POINT MOUNT SRB
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MAIN SHAFT SRB â OBSERVED DAMAGE MODES:LOW SPEED AND HIGH THRUST COMBINED=⢠Micropitting
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x
MAIN SHAFT SRB â OBSERVED DAMAGE MODES:LOW SPEED AND HIGH THRUST COMBINED=⢠Edge Loading
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MAIN SHAFT SRB â OBSERVED DAMAGE MODES:LOW SPEED AND HIGH THRUST COMBINED=⢠Single Piece Cage Damage
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MAIN SHAFT SRB â OBSERVED DAMAGE MODES:LOW SPEED AND HIGH THRUST COMBINED=⢠Debris Damage
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MAIN SHAFT SRB ENHANCEMENTSEnhanced Geometry ⢠Reduce edge loading⢠Improves roller/race contact⢠Decreases roller stresses
x
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MAIN SHAFT SRB ENHANCEMENTSSurface Finish⢠Reduced asperity contact and stress⢠Higher surface film, lower torque⢠Reduce friction and wear
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MAIN SHAFT SRB ENHANCEMENTSTwo Piece Cage:⢠Lower operating forces/stress
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MAIN SHAFT SRB ENHANCEMENTSWear Resistant âDLCâ Coatings⢠Mitigate surface wear damaged⢠Increase fatigue life⢠Increase debris resistance
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TECHNOLOGY DESCRIPTION BENEFITS
Roller Finishing Low Roughness,Isotropic Finish
Reduced Asperity Contact & Stress
Roller Coating WC/aC:H Coating1 Âľm thick
Increased Wear Resistance,Increased Fatigue Life,Increased Debris Resistance.
Internal Geometry Roller/IR Conformity Decreases Roller Stress,Reduces Potential Roller SkewCreates Favorable Traction
Split Cage Two-Piece Machined Brass Cage
Lowers Possible Operating Forces
TIMKEN WEAR-RESISTANT SRBWear Resistant SRB
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Grease / Debris
Race condition
RESULTS OF TIMKEN WEAR RESISTANT SRBS AFTER 4 YEARS OPERATION
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MAIN SHAFT BEARING HEALTH- OTHER FACTORS⢠Condition Monitoring
⢠Statistical analysis and trending of bearing temperatures⢠Vibration or Shock Pulse analysis
⢠Lubrication Practices⢠Variation in manual greasing practices (amount & frequency)⢠Value of Auto-Lubrication systems
⢠Grease Selection⢠Investigate characteristics of current grease and alternatives
⢠Grease Flush⢠Designed to extend the life of bearings in early stages of wear
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High Speed & Intermediate shafts:⢠High occurrence Rate â˘Axial cracks on Inners
Planetary positions:⢠Medium occurrence Rate⢠Debris & load damage
WIND GEARBOX BEARINGSPlanet Carrier & Low Speed Positions:â˘Low occurrence Rateâ˘Thrust damage
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SRB CRB TRB
Integrated CRB Integrated TRB
PLANET BEARING ARRANGEMENTS - DEVELOPMENT
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PLANET BEARING - OBSERVED DAMAGE MODES
23
Non-Integrated Integrated
TRB ⢠Debris damage⢠Creeping Outer
⢠Debris damage
CRB ⢠Debris damage⢠Thrust load ⢠Heavy / Uneven loading⢠Smearing⢠Creeping outer
⢠Debris damage⢠Thrust Loading⢠Smearing
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PLANET BEARING ENHANCEMENTS⢠SRB:
⢠Replace with new design⢠CRB:
⢠Case carburized⢠DLC coating⢠Modified controlled clearances⢠Redesign as TRB or integrated
⢠TRB:⢠Case carburized⢠Redesign as integrated
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CRBCRB + ball bearing
HIGH SPEED AND INTERMEDIATE COMMON GEARBOX BEARING ARRANGEMENTS
Non-locating Position Locating Position Options
Double TRB
Single TRB
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HIGH SPEED & INTERMEDIATE BEARINGS â OBSERVED DAMAGE MODES
I
R
r
Rr
F
1. Smearing 3. White Etch AreaAxial Cracking / Flaking
2. Inclusion Related:Axial Cracking / Spalling
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ROLLER SLIDING / SMEARING IN CRB
IR
r
RIRR
r
Outer Race
Inner Race
Cage
Roller
D - roller sliding increases outside the load zone
C â load zone exit â most of the traction forces are lost beyond this point
F
B - traction forces restore roller velocity to pure rolling motion in load zone
Aâ smearing as roller accelerates entering the load zone
Load distribution in load zone
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INCLUSION RELATED AXIAL CRACKING⢠Caused by non-ferrous contaminants in the steel⢠Commonly manifests as White Etch Butterflies⢠Material transforms in the area of the inclusion⢠Crack forms and prorogates to the surface or spalls
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WHITE ETCH AREAS CRACKS1. Hoop Stress from original Press Fit on shaft2. Tensile stresses from roller sliding & skewing3. Dynamic conditions begin the subsurface
transformation4. Crack forms in the hard & brittle transformed area5. Crack propagates to the surface
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WHITE ETCH AREAS CRACKS2. Tensile stresses from roller sliding & skewing
IR
r
Rr
F
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WHITE ETCH AREAS CRACKS
3.
3. Dynamic conditions begin the subsurface transformation
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WHITE ETCH AREAS CRACKS
Dynamic Event
Dynamic Event
NormalLoad
NormalLoad
Plastic Deformation Transformation
Plastic Deformation Transformation
4.
4. Crack forms in the hard & brittle transformed area
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WHITE ETCH AREAS CRACKS
5.
5. Crack propagates to the surface
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BEARING ENHANCEMENTS - HIGH SPEED & INTERMEDIATEEnhancement White Etch Inclusions Smearing
Steel Cleanliness + +++
Black Oxide +(early stages)
++(early stages)
âDLCâ Coatings + +++
Case Carburized +++ ++
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0
1
2
3
4
Com
plet
ed Sm
earin
g Tes
t Cyc
les
Smeared during first cycle
ENGINEERED SURFACE: PERFORMANCE COMPARISON
Ground Honed/ES20 Honed/ES20/Black Oxide Wear-Resistant
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ENGINEERED SURFACES (COATINGS & TREATMENTS) Black Oxide Surfaces⢠Black oxide is a conversion treatment:
⢠Metallic parts are put into a hot bath containing oxidizing salts⢠Steel reacts with the oxidizing salts to form a
thin layer of magnetite on the surface (Fe3O4).
⢠Black oxide is a sacrificial surface⢠Benefits:
⢠Aesthetics⢠Corrosion prevention⢠Run-in and/or performance improvement⢠Prevents mild adhesive wear damage⢠Improve rolling contact fatigue life
DLC Coated Surfaces⢠DLC is a hard coating:
⢠Tungsten carbide incorporating an amorphous hydrocarbon composite. ⢠Applied with a Physical Vapor Deposition
process in a vacuum chamber.
⢠Benefits:⢠Improve rolling contact fatigue life.⢠Mitigate life limiting wear damaged caused by
metal adhesion.⢠Increased fatigue Life⢠Increased debris resistance⢠Prevent scuffing or smearing damage
(Timken Wear Resistant coating)
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Inner Race Subsurface Condition
Roller coating intact
RESULTS OF TIMKEN CRB (CASE CARBURIZED AND WEAR RESISTANT) AFTER 18 MONTHS
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GEARBOX BEARING HEALTH â OTHER FACTORS⢠Condition Monitoring⢠Oil analysis programs and Online oil monitoring systems⢠Vibration or Shock Pulse analysis
⢠Oil Selection ⢠Anti-Foaming⢠Additives / Properties
⢠Oil System Accessories⢠Moisture removal systems⢠Oil filtration systems
⢠Quality Oil Changes⢠Frequency based on oil monitoring condition⢠Vendor oil change features
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GENERATOR BEARING OBSERVED DAMAGE MODESâ˘Electrical Fluting â˘Inadequate Lubrication
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GENERATOR BEARING ENHANCEMENTS⢠Add on shaft grounding ring ⢠Upgrade the ground brushes from carbon to metal fiber⢠Upgrade bearings from metal/ceramic coated to ceramic balls
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Generator Bearings
Gearbox High Speed Bearings
Gearbox Planet Bearings
Main Shaft Bearings
WIND TURBINE DRIVETRAIN - SUMMARY BEARING DAMAGE AND UPGRADESâ˘Wear Resistant coating
â˘Case Carburizedâ˘Controlled clearance
â˘Grounding improvementsâ˘Ceramic balls
â˘Case Carburizedâ˘Wear Resistant coating
â˘Wear Resistant coatingâ˘Two piece cageâ˘Geometry enhancements
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Questions?Paul Dvorak Windpower Engineering & [email protected]: @Windpower_Eng
Rick BrooksThe Timken [email protected] Phone: 330-471-7812
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Thank You This webinar will be available at
www.windpowerengineering.com & email Tweet with hashtag #WindWebinar Connect with Windpower Engineering &
Development
Discuss this on the EngineeringExchange.com