Improving the reliability of industrial multi-MW wind turbines

Jun Zhou; Sanaz Roshanmanesh; Farzad Hayati; Valter Luiz Jantara Junior; Taoran Wang; Siavash Hajiabady; Xiaoying Li; Hector Basoalto; Hanshan Dong; Mayorkinos Papaelias

doi:10.1784/insi.2017.59.4.189

Improving the reliability of industrial multi-MW wind turbines

Jun Zhou, Sanaz Roshanmanesh, Farzad Hayati, Valter Luiz Jantara Junior, Taoran Wang, Siavash Hajiabady, Xiaoying Li, Hector Basoalto, Hanshan Dong, Mayorkinos Papaelias

Research output: Contribution to journal › Article › peer-review

7 Citations (Scopus)

398 Downloads (Pure)

Abstract

Although wind turbine gearboxes are designed to remain in-service for 20-25 years, this is not normally the case due to defects initiating and developing prematurely. A large number of gearboxes fail after 7 to 8-years in service. In offshore wind farms gearbox failures have been reported after only 1-2 years in service leading to noteworthy production losses. Reliability issues associated with wind turbine gearboxes are yet to be resolved. Within this paper the quality of materials used for manufacturing wind turbine gearbox gears and bearings has been evaluated. The damage mechanisms affecting gearbox materials have been investigated based on metallographic analysis carried out on failed samples removed from in-service industrial wind turbines. Finite Element Analysis (FEA) has been carried out in order to simulate damage initiation and propagation under in-service conditions. The results have been compared with the experimental observations made on the failed field samples and have been
found to be in good agreement. The applicability of acoustic emission in detecting and identifying defects in different wind turbine gearbox components remotely has been assessed following measurements in the field.

Original language	English
Pages (from-to)	189-195
Number of pages	7
Journal	Insight - Non-Destructive Testing and Condition Monitoring
Volume	59
Issue number	4
DOIs	https://doi.org/10.1784/insi.2017.59.4.189
Publication status	Published - 1 Apr 2017

Keywords

condition monitoring
acoustic emission
Wind turbines
gearbox
FEA

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Accepted author manuscript, 756 KBLicence: Creative Commons: Attribution-NonCommercial (CC BY-NC)

Cite this

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title = "Improving the reliability of industrial multi-MW wind turbines",

abstract = "Although wind turbine gearboxes are designed to remain in-service for 20-25 years, this is not normally the case due to defects initiating and developing prematurely. A large number of gearboxes fail after 7 to 8-years in service. In offshore wind farms gearbox failures have been reported after only 1-2 years in service leading to noteworthy production losses. Reliability issues associated with wind turbine gearboxes are yet to be resolved. Within this paper the quality of materials used for manufacturing wind turbine gearbox gears and bearings has been evaluated. The damage mechanisms affecting gearbox materials have been investigated based on metallographic analysis carried out on failed samples removed from in-service industrial wind turbines. Finite Element Analysis (FEA) has been carried out in order to simulate damage initiation and propagation under in-service conditions. The results have been compared with the experimental observations made on the failed field samples and have beenfound to be in good agreement. The applicability of acoustic emission in detecting and identifying defects in different wind turbine gearbox components remotely has been assessed following measurements in the field. ",

keywords = "condition monitoring, acoustic emission, Wind turbines, gearbox, FEA",

author = "Jun Zhou and Sanaz Roshanmanesh and Farzad Hayati and {Jantara Junior}, {Valter Luiz} and Taoran Wang and Siavash Hajiabady and Xiaoying Li and Hector Basoalto and Hanshan Dong and Mayorkinos Papaelias",

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AU - Zhou, Jun

AU - Roshanmanesh, Sanaz

AU - Hayati, Farzad

AU - Jantara Junior, Valter Luiz

AU - Wang, Taoran

AU - Hajiabady, Siavash

AU - Li, Xiaoying

AU - Basoalto, Hector

AU - Dong, Hanshan

AU - Papaelias, Mayorkinos

PY - 2017/4/1

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N2 - Although wind turbine gearboxes are designed to remain in-service for 20-25 years, this is not normally the case due to defects initiating and developing prematurely. A large number of gearboxes fail after 7 to 8-years in service. In offshore wind farms gearbox failures have been reported after only 1-2 years in service leading to noteworthy production losses. Reliability issues associated with wind turbine gearboxes are yet to be resolved. Within this paper the quality of materials used for manufacturing wind turbine gearbox gears and bearings has been evaluated. The damage mechanisms affecting gearbox materials have been investigated based on metallographic analysis carried out on failed samples removed from in-service industrial wind turbines. Finite Element Analysis (FEA) has been carried out in order to simulate damage initiation and propagation under in-service conditions. The results have been compared with the experimental observations made on the failed field samples and have beenfound to be in good agreement. The applicability of acoustic emission in detecting and identifying defects in different wind turbine gearbox components remotely has been assessed following measurements in the field.

AB - Although wind turbine gearboxes are designed to remain in-service for 20-25 years, this is not normally the case due to defects initiating and developing prematurely. A large number of gearboxes fail after 7 to 8-years in service. In offshore wind farms gearbox failures have been reported after only 1-2 years in service leading to noteworthy production losses. Reliability issues associated with wind turbine gearboxes are yet to be resolved. Within this paper the quality of materials used for manufacturing wind turbine gearbox gears and bearings has been evaluated. The damage mechanisms affecting gearbox materials have been investigated based on metallographic analysis carried out on failed samples removed from in-service industrial wind turbines. Finite Element Analysis (FEA) has been carried out in order to simulate damage initiation and propagation under in-service conditions. The results have been compared with the experimental observations made on the failed field samples and have beenfound to be in good agreement. The applicability of acoustic emission in detecting and identifying defects in different wind turbine gearbox components remotely has been assessed following measurements in the field.

KW - condition monitoring

KW - acoustic emission

KW - Wind turbines

KW - gearbox

KW - FEA

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DO - 10.1784/insi.2017.59.4.189

M3 - Article

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JO - Insight - Non-Destructive Testing and Condition Monitoring

JF - Insight - Non-Destructive Testing and Condition Monitoring

IS - 4

ER -

Improving the reliability of industrial multi-MW wind turbines

Abstract

Keywords

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