风电机组维护与诊断––现状、难点、经济效益

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1、风电机组维护与诊断 m 现状、Winergy, 2010-1 -难点、经济效益威能极（天津）风力发电驱动有限公司 西门子（中国）研究院威能极的风电机组传动链解决方案winergy新产品研发/ R&D-威能极代表着当今最先进的风电机组齿 轮箱设计-已成功实现了 6MW齿轮箱原型样机优化风电机组的能量传输：先进的在线自动状态诊断系统变桨系统和控制器15%的威能极员工常年投身工程应用、研发和测试工作能够提供完整的风电机组传动链产品，同时提供电变桨系统和状态诊断系统Winergy, 2010主要内容winergy威能极：知名风电部件供应商winergyWinergy, 2010-4-主要内容winer

2、gyWinergy, 2010-4-主要内容winergySIEMENS工业集团能源集团医疗集团研究院Industry AutomationFossil Power GenerationImaging & IT德国传动部Renewable EnergyWorkflow & Solutions美国Buildi ng Tech no logiesOil & GasDiag no sties中国Industry SolutionsPower Tan smissi on英国OsramPower Distribution印度Mobility大型传动部winergy运动控制系统部机械传动部预知维护与振动监

3、测技术“现状难点-技术和管理经济效益分析Winergy, 2010-4-关键部件winergy维护策略响应式维护运行到故障发生对于关键部件-高成本: -吊车租用修理/解体发电量损失-安全风险预防性维护对于关键部件一成本较低-只在需要吋进行维护-早期发现故障降低吊车/修理费用问题在于：如何准确知道机组关键部件的状态?T振动监测与诊断:在线采集机组振动信号，通过分析主传动链振动，诊断主轴承、齿轮箱、发电机的缺陷，从而为维护工作提供依据在风力发电机组20年设计寿命中，齿轮箱与发电机维护费用占风机所有部件维护费用的 60%以上。因此，振动监测/诊断系统将齿轮与发电机选为重要的监测诊断对象。齿轮箱发电机

4、部件维护费用，按系统分类（总计20年内）刹车与液压系统6%控制系统数据来源：NREL, 2006（包括更换部件费用）Winergy, 2010-6 -振动监测技术-传感器振动标准 VDI 3834 Part 1 - Measurement and Evaluation of the Mecha nical Vi brat i on of Wind Energy Turbines and Their Comp orients “Winergy, 2010Winergy, 2010Winergy, 2010winergy振动监测技术-数据分析winergyDisplay of the tooth

5、damage (see photo on right) In the Time signal. In the cep strum and in the envelope spectrum一级：振动速度值，宽带（101kHz）RMS值的阈值监测，阈值的设置标准VDI 3834-1二级：振动速度/加速度，窄带（根据特征频率选择）RMS值的阈值监测进一步分析频谱三级：深入诊断（故障位置、类型）方法包括：频谱、包络谱、时间序列分析等VDI 3834-1: Measurement and evaluation of the mechanical vibration of wind energy turb

6、ines and their components On shore wind en ergy turbi nes with gearsISO 10816-3: Mechanical vibration Evaluation of machine vibration by measurements on non-rotating parts In dustrial machi nes with nominal power above 15 kW a nd nominal speeds betwee n 120 r/min and 15 000 r/min when measured in si

7、tuWinergy, 2010-9 -振动监测技术-现状信号采集+基本分析+人工诊断winergy自动诊断典型故障+人工诊断疑难杂症硬件 WinTControl 8个振动加速度通道获得GL认证和Allianz保险公司认证)软件 0mniTrend基本分析功能(FFT5 etc.) 可通过Modem远程访问专家远程分析数据提供诊断报告提供处理建议提供具有故障识别及故障定位功能 的自动故障诊断早期发现风机驱动链内的各种机械 故障自动预测风机部件的可安全运行剩 余寿命以易于理解的简洁文本形式描述故 障类型与故障位置基于互联网WWW远程访问Winergy, 2010-11 -自动诊断报告winergy

8、Winergy, 2010-12-自动诊断报告winergy自动生成诊断报告（趋势图、结论、预测、建议）wineS)winergyHealth Report: :鯉極CHINAProject:XXX Project Coenpentnt Lwal ReportPeriod:2009-12-09 13:07 2010-0-09 137Responsibte:Dete:2010413-09 13:08Health Status for WM Park:DWrtbutton:Overal Conclusion:Faulti prwdlcted lor wind turblnM：Symptom Str

9、ength Trends:G76 AD Output Shaft SUarina 1 RoIlM03-090J-1S20003 0 M-D12-M05-010t2312-W03-0101-23OJ-1520OV20SO M D03-09WP Guszliou WTG76 No forecart(tet Rofng Elarmnt DefectThe vyniptomB of RoMng Btmant Defect may b vtaudlaad by oMnmo the Prdkt racommended to plsn tot correcttve actio1.2 Section: WP.

10、Guazhou WTG76 GenenThe section *DetaUed Health Status* contains a detailed status dr maintenance problems. For all diagnoses, trend plots of the corre wind turbines without indications of any problems, no further staiComponentOUCfiyuiDiao*)osisCoupling-RE&DE0.29Inne* Race Defect Eady state of Inner

11、Race Defert.Shaft-Shaft (Sample)0.12Asynchrooou s Generator-Stnjctural parts-0.04Description: Generator wh R8Furthermore, in th s report, the Enwlcp Order Spectrum vrth 3 21B-282 order bsnd-pass f ter (E0S2) is an3 yzed to verify the detected defects, as shown n the follcv/ing plot and table. Tne Ch

12、aracteristic Frequences (CFs) of lnn& Race Defect and Rolling Element Ddfoe: aro iktod in :ho follcwin table AeecrdinglyCFc can ha found in thefo bwinj E0S2 pic*, and they are very close to the frequencies rrarked with cirscr 1 to cursor 4. which are much h gher than irost of other Sequences. Deiaie

13、d values can be fojnd ir xne following uoie As there is nearly no dinerenoe between ：he CF of nner Race Defect and that cf Rolling Element Defect, tnese large CFs pe3ks may be caused by theInner Race Defect and / o Rc： ng elemen: Defect.CFsX1X2X3X5XInner Race Defect481e.6214.4324.05RoHr? Element Def

14、ect4 72e.4414.1623.6Cursor No.1234eak -reaences cetecd4.736948714.22223.693Comparison of CFs of ronng dement defects and pcsk frequencies found in 032Characristic Frequency Configuration of Generdtor Drhren Erd BearingWinergy, 2010-13-主要内容winergy国内风电场目前基本采用小件“响应维护”，大件“定期维护”的模式通常问题比较严重了才被发现，例：齿轮箱高速端轴

15、承/齿轮从2008年起，国内龙源、国华、中节能、粤电等风电运营企业开始尝 试将主传动链的振动监测分析引入机组维护工作体系目前仍没有大规模釆用，既有技术也有管理流程的原因在欧洲，兆瓦级风力发电机组被强制要求具有状态监测功能欧洲的保险公司与风机认证机构要求在线状态监测系统作为风力发电机组标准系统配 置的一部分：口认证机构包括：口保险公司包括；Allianz Allianz(fij) Gothaer (Sotl|QPrRoyal & Sun Alliance RS疋Allianz要求参险风机驱动链中的所有轴承在运行40,000工作小吋或5年后必须强制更 换，除非参险风机中已经安装经过认证的状态监测系

16、统。预知维护与振动监测技术“现状 难点-技术和管理经济效益分析Winergy, 2010-15-难点二：机组运行工况划分winergy兆瓦级风电机组基本都是变速运行转速的改变会“抹掉”振动信号中的有用信息AuioSpecUMin.NFFT r.13? Owl.* 163MAiS.pectnim . N FFT -NM0-1 OvL- UlftiIdK M M M w J f-T3asvFixed Speed12% Speed Variation2000 MOT 4000 SW0 WM 7W0 8WC 9W0$gqucyW8-.44X 3SPZP4 唱LANWindparkGearboxCont

17、rollerGeneratorConverterElectrical EquipmentGrid AccessPitchYawAcc. Sensors风力发电机组状态诊断可以带来的收益winergy预知维护与振动监测技术“现状 难点-技术和管理经济效益分析安装使用风力发电机组状态诊断系统，通过尽早发现故障，监测 故障程度发展趋势，预测故障维修时间，从以下几个方面为风力发电 机组的运行维护节约费用支出：避免早发故障导致更为严重的故障破坏便于提前计划组织维修设备与维修人员便于提前安排备件采购减少不必要的部件更换，以降低维修费用与停机时间便于统筹安排多台风机的部件更换，以降低总体吊车使用费用 和准备

18、时间Winergy, 2010-19-早期发现故障避免高维修成本winergyWinergy, 2010-20-早期发现故障避免高维修成本winergy轮齿表面缺陷早 期,I行星齿轮表面有I零星剥落大面积齿面损伤1断齿塔顶可维修需吊到地面j反厂大修11避免早发故障导致更为严重的故障破坏，尽量在塔上进行维修威能极厂内定义的齿轮箱损伤级别 1级：所有主要部件可重用 2级个主要部件损坏，其它可重用 3级:23个主要部件损坏，其它可重用 更换齿轮箱：壳体损坏或4个及以上主要部件损坏Winergy, 2010-21-案例：GE1.5MW机组齿轮箱损坏winergyEarly prediction(Up-

19、tower repairs)Estimated costs ()High Speed Bearings4000High Speed Stage10.000IM Stage including: IM pinion23.000 Bearing 451 IM bearing 450 & 452LS bearing 3503.500Generator bearingsMain bearing?Planetary bearings20.000Consequential damage (Down-tower repairs)Estimated costs ()Gearbox rebuild (DC 1)

20、73.000Gearbox rebuild (DC 2)81.000Gearbox rebuild (DC 3)93.000New gearbox125.000Winergy, 2010-22 -案例：GE1.5MW机组齿轮箱损坏winergyWinergy, 2010-# -案例：GE1.5MW机组齿轮箱损坏winergyNote: Cane, labour, tools and travel expenses are not consideredNote: Energy/revenue loss is not considered.1) Prediction on generator be

21、aring failures remedied in time versus damaging generator shaft2) Predictio n and excha nge main bearing to a refurbished main shaft or grease b earing on -site. Con seque ntial damage is removing and refurbish main shaft and gearbox. On-site crane is required in both cases.Prediction on planetary b

22、earings at Damage Class 1 versus consequential damage at Damage Class 2 or 3.Winergy, 2010-# -案例：SWP3.6MW机组齿轮箱损坏winergyEarly prediction(Up-tower repairs)Estimated costs ()High Speed Bearings35.000High Speed PinionIM Stage including: IM pinionNo IMS High Speed Gear Bearing 451 IM bearing 450 & 452 LS

23、 bearing 350Generator bearirigsMain bearing?Planetary bearirigsConsequential damage (Down-tower repairs)Estimated costs ()Gearbox new360.000Gearbox rebuild (small failure)90.000Winergy, 2010- 23-案例：SWP3.6MW机组齿轮箱损坏winergyWinergy, 2010- #-案例：SWP3.6MW机组齿轮箱损坏winergyNote: Cane, labour, tools and travel e

24、xpenses are not considered Note: Energy/revenue loss is not considered.1) Prediction on generator bearing failures remedied in time versus damaging generator shaft2) Predictio n and excha nge main bearing to a refurbished main shaft or grease bearing on -site. Con seque ntial damage is removing and

25、refurbish main shaft and gearbox. On-site crane is required in both cases.Predictio n on plan etary bearings at Damage Class 1 versus con sequential damage at Damage Class 2 or 3.Winergy, 2010- #-风机齿轮箱和发电机故障率以及齿轮箱故障类型winergy在风机第4个运行年中，齿轮箱过早 故障的平均发生率为003次/年/台风机， 发电机为004次/年/台风机。大部分齿轮箱故障发生在高速级和行 星级区域，大

26、部分齿轮箱零件故障是轴承故障。Winergy, 2010-24 -风机齿轮箱和发电机故障率以及齿轮箱故障类型winergy忌医3/曲赵齿轮箱故障率运行时间（年）0.1200.1000 0800.060 0.0400.020 0 000发电机故障率运行时间（年）101520常规故障过早故障赠势数据来源：NREL, 2008Winergy, 2010-25 -计划与非计划齿轮箱故障维修费用对比winergyWinergy, 2010-26 -计划与非计划齿轮箱故障维修费用对比winergy非计划齿轮箱维修费用(1500KW)齿轮箱被吊下更换維修,无时$5,254 (2为吊车费用$151.900 (

27、72为非计划維修导致的 发电收入损失非计划錐修费用$56400 (26为总费用:$213,154$469 为$56.000 (27为吊车费用$151,900(73计划錐修导致的 发电收入损失计划維修费用辻划齿轮箱维修费用(1500kW) 齿轮箱被吊下更换维修,有劄牛总费用:$208,369注释:计划齿轮箱维修费用(1500kW) 风机机舱内实施齿轮箱维修$469 ($86.800 (99为总费用：$87,269计划维修导致的发 电收入损失计划维修费用当齿轮箱高速轴轴承发生故障时，可以在风机机舱内实施更换维 修。I大I此，若在该轴承故障导致齿轮箱发生更为严重的破坏性故 障之前更换维修，则可以节省

28、大量吊车费用和维修费用。按照15小时的停机时间计算因机舱内维修或现场已有吊车与备件 情况下的计划维修导致的发电收入损失。按照7天停机时间计算rh非计划维修导致的发电收入损失。数据来源：EPRI, 2006Winergy, 2010-27 -创造效益齿轮箱整体吊装维修平均维修费用（含吊车与人工费）RMB 1,200,000风机齿轮箱故障率003次/年冶使用状态诊断系统，齿轮 箱维修费可平均节省59%已安装风机估计总量20000 台Winergy, 2010-28 -winergy4駡约齿轮存7维修费用 节约齿轮箱p维修费用424-80(X000 元/每总结预知维护如果得以实施，可以创造巨大的经济

29、效益难点在于技术和管理两方面威能极能够提供从状态诊断系统到维修的全流程服务, 帮助风电场采用预知维护，降低机组维护成本winergyRemote Monitoring /Wind Fleet ManagementAdvanced CMPitch, Controller, SC AD A, Yaw,Converter, Elec. Parts, Grid AccessLoadMonitoringOilMonitoringsluelueeu)a)o(ls 6U0-JVibration Monitoring Drive TrainMain Shaft, Gearbox and Generator=Product Roadmap=Remote Monitoring and Preventive ExchangeServicesWinergy, 2010-27 -