Day1 sessioniv 03_skf_dunn_greiner

05 October 2011 © SKF Group Slide 0

Main Bearing Preventive
Maintenance & Condition
Monitoring Techniques
NREL CBM Workshop 2011
Korey Greiner and Mark Dunn

Typical maintenance techniques today
Maintenance strategies to improve reliability
Preventive
– Manual inspection of bearing
– Re lubrication of bearing
Predictive
– Continuous condition monitoring
Typical maintenance techniques today
– Manual re lubrication - 6 & 12 months scheduled maintenance
– Automated lubrication
– Some utilizing condition based monitoring

1Main Bearing Inspection and
Maintenance

Example 3 point bearing system
Increasing number of main bearing failures in the market
Root cause still under investigation
Lubrication is one possible cause
Heavy loads on Down wind side of bearing
Light load on upwind side of bearing
Upwind Side Load Zone

Grease separation - a growing concern
Grease separation
– Oil separating from thickener
– Thickener hardening
– No “mixing”
Hardened grease preventing proper
lubrication
– Blocking the bearing grease path(W33
groove)
Corrective measures
– Manual inspection of bearings every two
years (once if auto lubrication system is
used)
– Increase grease quantity to 100% fill
– Increase schedule manual relubrication
– Good experience with NLGI 1 grease
due to easier pumpablity, shear
characteristics and ability to operate all
weather conditions

Manual Inspection of Bearing
On Models that the front cover can be
removed
Grease
– Condition and amount
– Grease path
– Grease Samples
– Remove old grease
Bearing
– Measure internal clearance
– Inspect inner and outer of bearing for
damage (spalling, fragment denting, etc)
– Inspect rollers (Smearing on face, fragment
denting, etc)

Re lubrication
Manually grease bearing using the
inlet port at the top of the bearing
– Grease should emerge from center of
bearing
– Remove any old grease pushed from
inside bearing.
– Grease can now be hand packed
– Reassemble Bearing
– Continue to add grease until new grease
comes out of portal at the bottom of
housing

Bearings that can not be disassembled
Contact bearing manufacture for
calculation of 100% Free space fill
Open the grease outlet at the bottom
of housing
Pump calculated amount of grease
into housing inlet
If possible rotate Shaft several times
When new grease begins to come
out of outlet.
Rotate shaft for several minutes and
replace plug in outlet

Auto Lubrication Systems
Benefits of Auto Lubrications
– Small amount of grease added
often (1 minute every 6 hours)
– Reduced heat
– Reservoir will hold enough grease
for a year or more
– Using the IFM module grease will
be added only while turbine is
operating
– Reduced cost
Less waste, buy in bulk, reduced man
hours

Summary - Main Bearing Inspection and
Maintenance
 Root cause failure still under investigation, Lubrication is one possible
cause
 Recommend manual inspection every 2 years if continuing with manual
re lubrication
 Recommend manual inspection before installing auto lubrication system
 Small amount of grease added daily reduces heating, oil separation
(hardening), Improves oil film.
 Proper lubricating procedures will increase bearing life

2Main Bearing
Condition Monitoring

Condition monitoring at the main bearing
Challenges,
Slow rotating bearing
Variable speed and load conditions
Relatively low shaft rotational speed – typically < 20
rpm
Transmitted vibration (tower resonance, gearbox, etc.)
Changing ambient temperature
All points influence the vibration values

Methods for predictive maintenance
Different methods/techniques used to measure the
condition,
Temperature
Lubrication (grease) analysis
Overall Vibration values
Spectral analysis
Main bearing and rotor
Main bearing

On-site preparation/sensor location
2 Sensors recommended > axial and radial directions
Low frequency sensors required to detect running speed frequency
Sensors should have a high sensitivity to detect bearing failures (low energy)
Sensor locations at the main bearing

Requirements of the condition monitoring
system
Minimum 16 bit dynamic resolution, better 24 bit
New CMS should have order tracking
Spectra and trend data should recorded at similar
conditions
Benefit of “active ranges”:
-Saved spectra without “smearing” if used with allowed delta
-Better stable trend values – no up and down
-No grab spectra

Measurement setup – slow speed
-Due to the slow speed, a long measurement time is needed
-Min. 12 main shaft revolutions should be taken inside the meas.
time
-Fmax should include the 4. harmonic defect frequency
Order tracking setup

Example of a main bearing defect
Turbine data:
-1.5 MW turbine
-Life time 9 years
-Onshore
-Three point bearing design (1 main bearing / gearbox)
-Spherical Roller Bearing
-Similar to several main bearing defects

Comparison of different trend data
velocity trend
acceleration trend
Overall trends are not reliable to track main bearing issues.
Good for rotor/blades and tower vibration
Gearbox and main bearing changed
12.03.09

Envelope Trend (envelope filter -200Hz)
Gearbox and main bearing changed
Trend values decrease after change
The envelope trend value is more appropriate to detect bearing failures

Main bearing defect – acceleration spectra
Outer ring defect
Outer ring defect with harmonics
Inner ring defect frequency
with rotor speed spaced sidebands

Diagnostic techniques in SKF software
First overrun frequencies detected
One year before bearing
replacement – report to customer
Trend values increased, until maintenance
Main bearing replacement was merged together
with the planned gearbox exchange
Values drops down after maintenance
Benefit: Gearbox replace could be merged together with the main bearing replacement
Diagnosis trend:
Software generated band values around the bearing defect values
It is possible to track the defect development
Analysis is performed automatically by the software – reduces the needed analysis time

Pictures of the damaged bearing

Condition Monitoring Summary
Main Bearing defect analysis/identification is achievable
Accurate & reliable main bearing defect analysis is not easy
SKF have proven reliable techniques, along with specific
application experience to analyze and detect main bearing defects
Most main bearing defects visible in axial and radial directions
Best to measure in acceleration spectrum
Most main bearing defects exhibit low fundamental bearing defect
frequency amplitudes, compared to the harmonics
At low wind classes (low load), the defect is often more
visible/easier to diagnose (less transmitted frequencies)

Next Steps…….
Connecting Technologies…..

Connecting Condition Monitoring & Auto
Lubrication
+ +
WindCon WindLubObserver software

Working principle
Enveloped
acceleration
IMx-W relay driver
Time (t)
Lubrication cycles
Alarm/warning threshold value
Normal lubrication period
Relay / timer
modules
Additional lubrication cycle

Thank you – any questions please
?

Day1 sessioniv 03_skf_dunn_greiner

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