Detect WTG gearbox damage
for better planned maintenance and reduced repair costs
Bearing damage is one of the leading causes of unplanned gearbox removals which can lead to huge production loss. Missing early warning signs of gearbox failure could leave you with a down wind turbine waiting for a gearbox or crane.
Particle counters can provide 3 to 12 months warning in advance of failure which can help prioritise and plan a changeout campaign, reduce repair costs and minimise downtime.
What gearbox failure modes can we detect?
What can particle counters tell me?
- Counts 100% of particles above 125um Fe / 450um non-Fe (MS3505)
- Quantification of mass of particles liberated (g)
- Determine how much damage and damage progression
- Size of particles
- Ferrous and non-ferrous particles
- Monitor running in debris or gearbox wear
Remaining useful life of the gearbox
How does it work?
Our wind turbine gearbox particle counter detects and measures the particles using a three coil alternating current assembly as they pass through the sensor. The metallic particles disturb the magnetic field and produce a signal and the non-metallic particles produce an opposite signal. It measure both the size, count and mass of the particles and this data can be used to determine the failure mode and remaining useful like of the gearbox.
With GBX CMS
Without GBX CMS
How does particle counting compare to vibration CMS?
Why not both? The systems are complementary and you can easily integrate both hardware and software to provide more holistic condition monitoring.
Particle counting is cheaper!
Comparison
Particle Counting
Vibration CMS
Detection of early damage on high speed stage (HSS)
✔
✔
Detection of early damge on planetary stage
✔
X
Able to isolate location of damage
✔ (multi-sensor trending)
✔
Easy to interpret data
✔
X (requires expert interpretation)
Detection of gear tooth crack
✔ (some failure modes)
✔ (on HSS)
How do you install it?
Installation is less than a day using pre-fabricated joints and hoses to ensure seamless insertion into the oil circuit. We have previous experience on most turbine platforms having worked closely with the OEMs both in new turbines and oil debris sensing studies for a over a decade. The communications link can be established using open ports on the controller, existing CMS hardware or to our cloud service.
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