skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Monitoring of Wind Turbine Gearbox Condition through Oil and Wear Debris Analysis: A Full-Scale Testing Perspective

Abstract

Despite the wind industry's dramatic development during the past decade, it is still challenged by premature turbine subsystem/component failures, especially for turbines rated above 1 MW. Because a crane is needed for each replacement, gearboxes have been a focal point for improvement in reliability and availability. Condition monitoring (CM) is a technique that can help improve these factors, leading to reduced turbine operation and maintenance costs and, subsequently, lower cost of energy for wind power. Although technical benefits of CM for the wind industry are normally recognized, there is a lack of published information on the advantages and limitations of each CM technique confirmed by objective data from full-scale tests. This article presents first-hand oil and wear debris analysis results obtained through tests that were based on full-scale wind turbine gearboxes rated at 750 kW. The tests were conducted at the 2.5-MW dynamometer test facility at the National Wind Technology Center at the National Renewable Energy Laboratory. The gearboxes were tested in three conditions: run-in, healthy, and damaged. The investigated CM techniques include real-time oil condition and wear debris monitoring, both inline and online sensors, and offline oil sample and wear debris analysis, both onsite and offsite laboratories. The reportedmore » results and observations help increase wind industry awareness of the benefits and limitations of oil and debris analysis technologies and highlight the challenges in these technologies and other tribological fields for the Society of Tribologists and Lubrication Engineers and other organizations to help address, leading to extended gearbox service life.« less

Authors:
Publication Date:
Research Org.:
National Renewable Energy Lab. (NREL), Golden, CO (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Wind and Water Technologies Office (EE-4W)
OSTI Identifier:
1333276
Report Number(s):
NREL/JA-5000-67454
Journal ID: ISSN 1040-2004
DOE Contract Number:  
AC36-08GO28308
Resource Type:
Journal Article
Journal Name:
Tribology Transactions
Additional Journal Information:
Journal Volume: 72; Journal Issue: 10; Journal ID: ISSN 1040-2004
Publisher:
Taylor & Francis
Country of Publication:
United States
Language:
English
Subject:
17 WIND ENERGY; wind turbine gearbox; oil condition monitoring; oil debris monitoring; oil sample analysis; wear debris analysis

Citation Formats

Sheng, Shuangwen. Monitoring of Wind Turbine Gearbox Condition through Oil and Wear Debris Analysis: A Full-Scale Testing Perspective. United States: N. p., 2016. Web. doi:10.1080/10402004.2015.1055621.
Sheng, Shuangwen. Monitoring of Wind Turbine Gearbox Condition through Oil and Wear Debris Analysis: A Full-Scale Testing Perspective. United States. doi:10.1080/10402004.2015.1055621.
Sheng, Shuangwen. Sat . "Monitoring of Wind Turbine Gearbox Condition through Oil and Wear Debris Analysis: A Full-Scale Testing Perspective". United States. doi:10.1080/10402004.2015.1055621.
@article{osti_1333276,
title = {Monitoring of Wind Turbine Gearbox Condition through Oil and Wear Debris Analysis: A Full-Scale Testing Perspective},
author = {Sheng, Shuangwen},
abstractNote = {Despite the wind industry's dramatic development during the past decade, it is still challenged by premature turbine subsystem/component failures, especially for turbines rated above 1 MW. Because a crane is needed for each replacement, gearboxes have been a focal point for improvement in reliability and availability. Condition monitoring (CM) is a technique that can help improve these factors, leading to reduced turbine operation and maintenance costs and, subsequently, lower cost of energy for wind power. Although technical benefits of CM for the wind industry are normally recognized, there is a lack of published information on the advantages and limitations of each CM technique confirmed by objective data from full-scale tests. This article presents first-hand oil and wear debris analysis results obtained through tests that were based on full-scale wind turbine gearboxes rated at 750 kW. The tests were conducted at the 2.5-MW dynamometer test facility at the National Wind Technology Center at the National Renewable Energy Laboratory. The gearboxes were tested in three conditions: run-in, healthy, and damaged. The investigated CM techniques include real-time oil condition and wear debris monitoring, both inline and online sensors, and offline oil sample and wear debris analysis, both onsite and offsite laboratories. The reported results and observations help increase wind industry awareness of the benefits and limitations of oil and debris analysis technologies and highlight the challenges in these technologies and other tribological fields for the Society of Tribologists and Lubrication Engineers and other organizations to help address, leading to extended gearbox service life.},
doi = {10.1080/10402004.2015.1055621},
journal = {Tribology Transactions},
issn = {1040-2004},
number = 10,
volume = 72,
place = {United States},
year = {2016},
month = {10}
}

Works referenced in this record:

A comparative experimental study on the diagnostic and prognostic capabilities of acoustics emission, vibration and spectrometric oil analysis for spur gears
journal, January 2007

  • Tan, Chee Keong; Irving, Phil; Mba, David
  • Mechanical Systems and Signal Processing, Vol. 21, Issue 1
  • DOI: 10.1016/j.ymssp.2005.09.015

A brief status on condition monitoring and fault diagnosis in wind energy conversion systems
journal, December 2009

  • Amirat, Y.; Benbouzid, M. E. H.; Al-Ahmar, E.
  • Renewable and Sustainable Energy Reviews, Vol. 13, Issue 9
  • DOI: 10.1016/j.rser.2009.06.031

Sensitivity of RF Sensors for Bearing Health Monitoring
journal, September 2009


Condition monitoring and fault detection of wind turbines and related algorithms: A review
journal, January 2009


Identification of Single and Multiple Teeth Damage in a Gear Transmission System
journal, September 2006