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Wear Events StudyWind Turbine
Beinn An Tuirc–T12; Vestas V47, Moventas GBSensor Suite and Metallic Particle Sensor
Metallic Particle Sensor
Sensor Suite
GPRS Communications
Installation
Wear Debris Analysis
Wear Particle Size Being Generated
1. 1 10 100 1000
Microns
Catastrophic Failure
Advanced Failure Mode
Onset of Severe Wear Mode
Benign Wear
Wear
Part
icle
Con
cen
trati
on
Source Moubray et al
Wear Debris & Vibration
Wear Debris & Vibration
Wear Debris Sensor
Detects Metallic Wear Debris Particles in Oil
Reports Size, Number, Ferrous/Non-Ferrous & Rate
Early Detection of Increased Wear, Change in Wear Mechanism, Advanced
Wear and Catastrophic Wear
Wear Events – Wear Rate Vs Wind Speed
2nd Event1st Event
0
5
10
15
20
25
30
35
40
45
01/1
0/09
02/1
0/09
03/1
0/09
04/1
0/09
05/1
0/09
06/1
0/09
07/1
0/09
08/1
0/09
09/1
0/09
10/1
0/09
11/1
0/09
12/1
0/09
13/1
0/09
14/1
0/09
15/1
0/09
16/1
0/09
17/1
0/09
18/1
0/09
19/1
0/09
20/1
0/09
21/1
0/09
22/1
0/09
23/1
0/09
24/1
0/09
25/1
0/09
26/1
0/09
27/1
0/09
28/1
0/09
29/1
0/09
30/1
0/09
31/1
0/09
01/1
1/09
02/1
1/09
03/1
1/09
04/1
1/09
01/10/09 to 05/11/09Particles per minute AvgWindSpeed
2nd Event1st Event
3 Weeks
0
5000
10000
15000
20000
25000
30000
35000
01/1
0/09
02/1
0/09
03/1
0/09
04/1
0/09
05/1
0/09
06/1
0/09
07/1
0/09
08/1
0/09
09/1
0/09
10/1
0/09
11/1
0/09
12/1
0/09
13/1
0/09
14/1
0/09
15/1
0/09
16/1
0/09
17/1
0/09
18/1
0/09
19/1
0/09
20/1
0/09
21/1
0/09
22/1
0/09
23/1
0/09
24/1
0/09
25/1
0/09
26/1
0/09
27/1
0/09
28/1
0/09
29/1
0/09
30/1
0/09
31/1
0/09
01/1
1/09
02/1
1/09
03/1
1/09
04/1
1/09
01/10/09 to 05/11/09Ferrous particle count (40 to 60µm) Ferrous particle count (60 to 100µm) Ferrous particle count (100 to 200µm)
Ferrous particle count (200 to 300µm) Ferrous particle count (>300µm)
Wear Events – Particles Generated
2nd Event1st Event
3 Weeks
0
10
20
30
40
50
60
01/1
0/09
02/1
0/09
02/1
0/09
03/1
0/09
03/1
0/09
04/1
0/09
01/10/09 to 03/10/09Particles per minute AvgWindSpeed StdDevWindSpeed X10 AvgPitchAng
1st Event – Wear Rate Vs Wind Speed & Pitch
1st Event
0
10
20
30
40
50
60
19/1
0/09
20/1
0/09
21/1
0/09
22/1
0/09
23/1
0/09
24/1
0/09
25/1
0/09
26/1
0/09
27/1
0/09
28/1
0/09
29/1
0/09
30/1
0/09
31/1
0/09
01/1
1/09
02/1
1/09
03/1
1/09
04/1
1/09
05/1
1/09
19/10/09 to 05/11/09Particles per minute AvgWindSpeed StdDevWindSpeed X10 AvgPitchAng
2nd Event – Wear Rate Vs Wind Speed & Pitch
2nd Event
0
200000
400000
600000
800000
1000000
1200000
1400000
1600000
28/0
3/09
02/0
4/09
07/0
4/09
12/0
4/09
17/0
4/09
22/0
4/09
27/0
4/09
02/0
5/09
07/0
5/09
12/0
5/09
17/0
5/09
22/0
5/09
27/0
5/09
01/0
6/09
06/0
6/09
11/0
6/09
16/0
6/09
21/0
6/09
26/0
6/09
01/0
7/09
06/0
7/09
11/0
7/09
16/0
7/09
21/0
7/09
26/0
7/09
31/0
7/09
05/0
8/09
10/0
8/09
15/0
8/09
20/0
8/09
25/0
8/09
30/0
8/09
04/0
9/09
09/0
9/09
14/0
9/09
19/0
9/09
24/0
9/09
29/0
9/09
04/1
0/09
09/1
0/09
14/1
0/09
19/1
0/09
24/1
0/09
29/1
0/09
03/1
1/09
08/1
1/09
13/1
1/09
18/1
1/09
23/1
1/09
28/1
1/09
03/1
2/09
08/1
2/09
13/1
2/09
18/1
2/09
23/1
2/09
28/1
2/09
02/0
1/10
07/0
1/10
12/0
1/10
17/0
1/10
22/0
1/10
27/0
1/10
01/0
2/10
06/0
2/10
11/0
2/10
16/0
2/10
21/0
2/10
03/04/09 to 26/12/10Total Number of Particles Recorded
Wear Particles – Prior to System Swap
2nd Event1st Event
0
10
20
30
40
50
60
28/0
3/09
02/0
4/09
07/0
4/09
12/0
4/09
17/0
4/09
22/0
4/09
27/0
4/09
02/0
5/09
07/0
5/09
12/0
5/09
17/0
5/09
22/0
5/09
27/0
5/09
01/0
6/09
06/0
6/09
11/0
6/09
16/0
6/09
21/0
6/09
26/0
6/09
01/0
7/09
06/0
7/09
11/0
7/09
16/0
7/09
21/0
7/09
26/0
7/09
31/0
7/09
05/0
8/09
10/0
8/09
15/0
8/09
20/0
8/09
25/0
8/09
30/0
8/09
04/0
9/09
09/0
9/09
14/0
9/09
19/0
9/09
24/0
9/09
29/0
9/09
04/1
0/09
09/1
0/09
14/1
0/09
19/1
0/09
24/1
0/09
29/1
0/09
03/1
1/09
08/1
1/09
13/1
1/09
18/1
1/09
23/1
1/09
28/1
1/09
03/1
2/09
08/1
2/09
13/1
2/09
18/1
2/09
23/1
2/09
28/1
2/09
02/0
1/10
07/0
1/10
12/0
1/10
17/0
1/10
22/0
1/10
27/0
1/10
01/0
2/10
06/0
2/10
11/0
2/10
16/0
2/10
21/0
2/10
03/04/09 to 26/12/10Particles per minute(D) ()
Wear Rate – Prior to System Swap
2nd Event1st Event
Inspection
Post Event Gearbox Inspection (10/02/10)
Magnetic Dip-Stick
Ferrous Metallic Wear Debris Evident
High Speed Shaft Roller Element
Circumferential Surface Scoring Evident
Shaft Gears
Slight Scuffing Evident
Post Event Laboratory Report
Lubricant Sample
Iron 20ppm
Non-Ferrous Metallic
Elements all <1ppm
Post Event Laboratory Report
Filter Analysis
Previous Filter = 22mg Wear Debris
(3 Months Use)
“Event” Filter = 59mg Wear Debris
(3 Months Use)
Filter Back-Washed and Analysed by SEM
>40% of Debris: “Flakes and Slivers of
Iron up to 1.6mm x 0.4mm”
Example Filter Debris - Ferrous Metallic
Example Filter Debris – Non-Ferrous Metallic
Pre Wear Event Filter Analysis
Sliding Wear Sliding Wear
Sliding Wear Sliding Wear SEM pictures produced by
Example Filter Debris - Ferrous Metallic
Example Filter Debris – Non-Ferrous Metallic
Post Wear Event Filter Analysis
Cutting Wear Sliding Wear
Possible Cutting Wear Sliding Wear SEM pictures produced by
