www.parker.com/hfde - Dr. Steve Dye, Business Development and Marketing Manager of Parker Hannifin's Kittiwake Division presented at Hannover Messe 2013. Conclusions of the presentation are that wear debris detection is effective at picking up early signs of damage within wind turbine gear boxes. In addition, particle size increases as severity of damage increases - earliest detection provided by the smallest particles.

1. Wind Turbine Condition Monitoring
Dr Steve Dye
Business Development and Marketing Manager, Condition
Monitoring Business Unit.

2. What does it offer? - Wear Debris & Vibration

3. Wear Debris Analysis
Wear Particle Concentration
Catastrophic
Failure
Advanced Failure Mode
Onset of Severe Wear Mode
Benign Wear
Microns
.1 1 10 100 1,000
Wear Particle Size Being Generated
Source Moubray et al

4. Wear Debris Sensor
• Detects Metallic Wear Debris Particles in Oil
• Reports Size, Number, Ferrous/Non-Ferrous & Rate
• Puts particle numbers into different “Bin’s” depending
on size and material composition (Fe vs. Non-Fe)
• Early Detection of Increased Wear, Change in Wear
Mechanism, Advanced Wear and Catastrophic Wear

5. Wear Debris Sensor Demonstration

6. 5
0
10
25
30
45
15
20
35
40
01/10/09
02/10/09
03/10/09
04/10/09
05/10/09
06/10/09
07/10/09
1st Event
08/10/09
09/10/09
10/10/09
11/10/09
12/10/09
13/10/09
14/10/09
3 Weeks
15/10/09
16/10/09
17/10/09
18/10/09
Particles per minute
19/10/09
20/10/09
21/10/09
22/10/09
01/10/09 to 05/11/09
23/10/09
AvgWindSpeed
24/10/09
25/10/09
26/10/09
27/10/09
28/10/09
29/10/09
30/10/09
Wear Events – Wear Rate Vs Wind Speed
31/10/09
01/11/09
02/11/09
2nd Event
03/11/09
04/11/09

7. Wear Events – Particles Generated
01/10/09 to 05/11/09
Ferrous 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)
35000
30000
25000
1st Event 2nd Event
20000
15000
10000
5000
3 Weeks
0
04/10/09
09/10/09
11/10/09
14/10/09
16/10/09
21/10/09
26/10/09
28/10/09
31/10/09
02/11/09
01/10/09
02/10/09
03/10/09
05/10/09
06/10/09
07/10/09
08/10/09
10/10/09
12/10/09
13/10/09
15/10/09
17/10/09
18/10/09
19/10/09
20/10/09
22/10/09
23/10/09
24/10/09
25/10/09
27/10/09
29/10/09
30/10/09
01/11/09
03/11/09
04/11/09

8. Post Event Gearbox Inspection
Magnetic Dip-Stick
Ferrous Metallic Wear Debris Evident
High Speed Shaft Roller Element
Circumferential Surface Scoring
Evident
Shaft Gears
Slight Scuffing Evident

9. 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”

10. Pre Wear Event Filter Analysis
Example Filter Debris - Ferrous Metallic
Sliding Wear Sliding Wear
Example Filter Debris – Non-Ferrous Metallic
Sliding Wear Sliding Wear

11. Post Wear Event Filter Analysis
Example Filter Debris - Ferrous Metallic
Cutting Wear Sliding Wear
Example Filter Debris – Non-Ferrous Metallic
Possible Cutting Wear Sliding Wear

12. Conclusions
• Sudden application of brake due to wind gust
caused stresses back through gearbox and
generator
• This caused thrust bearing housing to rotate in
its cast iron mounting – giving the resulting
cutting wear metallic particles in oil
• Wear Debris detection effective at picking up
early signs of damage within the gear box
• Particle size increases as severity of damage
increases – earliest detection of damage is
provided by detection of smallest particles
12

13. Questions?
13