Wind turbine condition monitoring sqi rev
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The document outlines a marketing research plan for Spectraquest Inc. focusing on wind turbine condition monitoring systems. It discusses the importance of condition monitoring for preventing machinery failures, highlights current competitors in the market, and details the company's unique advantages. Additionally, it addresses market objectives, technology trends, and the increasing demand for online monitoring solutions.
Wind turbine condition monitoring sqi rev
- 1. Suri Ganeriwala & Juli Hamlet SpectraQuest Inc. Richmond, VA Wind Turbine Condition Monitoring System Marketing Research
- 2. Outline: Introductory comments and motivation What is Condition monitoring Current Companies offering CMS SpectraQuest Advantage Marketing Research General Guidelines-our objectives
- 3. Introduction Generation of Energy is a prime factor for socioeconomic development Increasing demand of energy can not be completely fulfilled by Fossil Fuel based energy generation Non Conventional energy has tremendous potential as it can play a big roll in fulfilling the future energy requirement Development of modern technology is making the Non Conventional energy an efficient source of energy
- 4. Wind turbine production is one of the fastest growing industries
- 5. Rotor Blades 22.2 % Tower 26.3 % Gear Box 12.91 % Generator 3.44 % Power Converter 5.01 % Transformer 3.59 % Brake System 1.32 % Nacelle Housing 1.35% Yaw System 1.25 % Pitch System 2.66 % Main Frame 2.8 % Main Shaft 1.91 % Rotor Bearings 1.22 % Rotor Hub 1.37 % Wind Turbine Operation/Maintenance Cost
- 6. Wind Turbine Failure Types Gearboxes and drive trains have an annual failure frequency of ~0.10, and take an average 7 days to repair Composite rotor blades are also a common failure type with an annual failure frequency or ~0.15 Source: “Blade reliability initiative”, Paul Veers, Sandia National Labs
- 7. Wind Power Map in USA 8201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com
- 9. Why monitor machinery? Prevent catastrophic failure & significant damage Avoid loss of life, environmental harm, economic loss Stop unscheduled outages Optimize machine performance Reduce repair time and spare parts inventory Lengthen maintenance cycle Reduce scrap and raw material consumption Increase product quality Predictive Maintenance Production Assurance Safety Quality Control
- 10. Condition Monitoring: Condition Based Maintenance (CBM) promises to deliver improved maintainability and operational availability of rotating machinery while reducing life- cycle costs. The three critical components of CBM are: 1. Fault detection 2. Diagnostics: Determining exactly what is wrong 3. Prognostics: Determining fault severity and predicting remaining life
- 11. Condition Monitoring Three main steps: data acquisition, data processing and maintenance decision-making. Obtain data relevant to system health Handle and analyze the data Recommend efficient maintenance decision
- 12. Types of Monitoring Continuous Protection • Critical Machinery • Shut Down Systems • Class 1, Div 2 • API 670 • Balance of Plant • Availability • Maintenance • Balance of Plant • Maintenance Choose based on: • Safety • Failure Modes • Equipment Criticality Portable
- 14. Bearing Accelerometer Placement Accel X Accel Y Bearing Mount Bearing Accelerometer Accelerometer How does a bearing vibrate? www.pcb.com
- 15. Current Companies Offering CMS Bently Nevada (GE) Commtest (GE) Bruel & Kjaer Vibro Emerson Electric / CSI Rockwell Automation SKF Condition Monitoring / SKF Reliability Systems 01dB DLI Engineering/Azima National Instruments Pruftechnik
- 16. Vibration Monitoring Equipment Market 42% 10% 10% 10% 7% 6% 15% Bently Nevada SKF Condition Monitoring and Vibrometer Alliance Rockwell Automation Entek IRD Emerson Process CSI Bruel & Kjaer Vibro Shinkawa Electric Corporation Others
- 17. Vibration Monitoring Equipment Online Offline Handheld/Portable: walk- around monitoring Portable Diagnostics: boxes used for detailed test •2 to 4 channels •FFT display •$5k to $25k •4 to 24 channels •Lots of analysis and display •$5k to $50k Real-time Monitoring: network based nodes reporting trends and alarms Embedded Protection: machine shut-down based on key measurements •Distributed channels (4-100’s) •Most visualization options •$15k to $60k •High reliability •Most widely used scheme •$5k to $$25k
- 18. CSI/Emersion Electric – Models 1910 & 2130 1910 – Spectrum Analyzer 21 V input 72 dB dynamic range 12-bit A/D 2130 – Machine Health Analyzer 16 bit A/D 96 dB dynamic range Order Tracking, Coastdown, Bearing analysis Model 1910 Model 2130
- 19. SKF Condition Monitoring – Marlin/Microlog Input Voltage Range: 25 V peak AC, +/- 50 VDC 14 bit A/D 20 kHz signal bandwidth 80 dB dynamic range 60 dB of gain 6 MB (Flash 4 MB) memory Connectors: BNC (3) input, output, and tachometer/phase and multi-pin D connector. Tachometer: Minimum pulse amplitude 2 Vpp, 10% rise/fall time, minimum 0.1 ms pulse width MARLIN MCM Microlog CMXA50
- 20. Bently Nevada (Part of GE) – 3500 Series Over 24 modules Vibration Dynamic Pressure Temperature Process Variables Keyphasor input module: +0.8 to -21 V Input range of 1 to 1,200,000 rpm Signal range of 0.017 to 20 kHz
- 21. Bently Nevada (Part of GE) – System One SW Current version: 5.0 Process optimization Alarming, trending Exception reporting Web server SQL connectivity Equipment covered: Turbomachinery Compressors Wind Turbines “RulePaks” with stored diagnostics information
- 22. 8201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Blade Monitoring
- 23. Blade Test Setup Thirteen accelerometers were attached to the surface of the blade. The blade was impacted with an instrumented hammer at each end and in the middle.
- 24. Industry Trends Equipment Vendor Consolidation Consolidation has resulted in the acquisition of some of the key industry players by larger entities Shift from Offline to Online Monitoring Increasing need for Integration of Condition Monitoring systems with Plant Asset Management systems and CMMS towards monitoring of total asset health Demand for Vibration Consulting and Services Industry downturn and pursuit of cost optimization has resulted in manpower reduction in maintenance departments of organizations.
- 25. Technology Trends Tight integration into PAM/CMMS using standard communications protocols Internet as enabler Ethernet/networked vibration systems PC-centric vibration monitoring systems More widely accepted than in other industrial applications Advancements in sensor technology TEDS = simplified setup & increased accuracy
- 26. SpectraQuest Unique Expertise CMS: We already have individual components of a CMS We have advanced signal processing algorithms to ACCURATELY diagnose and predict failure time to schedule repair Access to the latest technology being developed by customers using test beds supplied by SQi Inspection & Training: We will also provide a new inspection and blade monitoring system (none exist today), Training SQi CAN offer a Total Solution
- 27. SpectraQuest Condition Monitoring System “WindQuest”
- 28. Online Monitoring and Alarming Location -> Machine train - > Sensor level conditions Color-coded Wind Turbine status User-customizable monitoring criteria, and alarm levels Click to view sensors’ current values, waveforms or spectra User-customizable raw data storing criteria Wind Turbine Measurement Configuration
- 29. System Structure On-site data acquisition/communication hardware Online monitoring/alarming, data archiving/trending, and reporting generation Advanced analysis software for analyst to perform in-depth diagnosis Remote monitoring and diagnostics capabilities Host Database server
- 30. Market Research Objectives Market Potential/Size How to enter market, are there any barriers? Market analyses (types of industries) Distribution Channels (Own sales office, Representatives, Distributors/Dealers) Representative Agreement, and other legal issues Competitors and their products Pricing, sales/distribution structure, how do they market Comparison of features, strengths
- 31. 31 THANKS SpectraQuest Inc. 8201 Hermitage Rd, Richmond, VA www. spectraquest.com Tell: (804) 261-3300 Fax: (804) 261-3303 suri@spectraquest.com