Francis Quail

Detailed State of the Art Review for the Different Online/Inline Oil Analysis Techniques in Context of Wind Turbine Gearboxes

The main driver behind developing advanced condition monitoring (CM) systems for the wind energy industry is the delivery of improved asset management regarding the operation and maintenance of the gearbox and other wind turbine components and systems. Current gearbox CM systems mainly detect faults by identifying ferrous materials, water, and air within oil by changes in certain properties such as electrical fields. In order to detect oil degradation and identify particles, more advanced devices are required to allow a better maintenance regime to be established. Current technologies available specifically for this purpose include Fourier transform infrared (FTIR) spectroscopy and ferrography. There are also several technologies that have not yet been or have been recently applied to CM problems. After reviewing the current state of the art, it is recommended that a combination of sensors would be used that analyze different characteristics of the oil. The information individually would not be highly accurate but combined it is fully expected that greater accuracy can be obtained. The technologies that are suitable in terms of cost, size, accuracy, and development are online ferrography, selective fluorescence spectroscopy, scattering measurements, FTIR, photoacoustic spectroscopy, and solid state viscometers.

Design optimisation of a regenerative pump using numerical and experimental techniques

Purpose – Regenerative pumps are the subject of increased interest in industry as these pumps are low‐cost, low‐specific speed, compact and able to deliver high heads with stable performance characteristics. However, these pumps have a low efficiency (35‐50 per cent). The complex flow field within the pumps represents a considerable challenge to detailed mathematical modelling. Better understanding of the flow field would result in improvement of the pump efficiency. The purpose of this paper is to consider a numerical and experimental analysis of a regenerative pump to simulate the flow field and math pump performance.Design/methodology/approach – This paper outlines the use of a commercial computational fluid dynamics (CFD) code to simulate the flow field within the regenerative pump and compare the CFD results with new experimental data. A novel rapid manufacturing process is used to consider the effect of impeller geometry changes on the pump efficiency.Findings – The CFD results demonstrate that it i...

Analysis of Offshore Wind Turbine Operation and Maintenance Using a Novel Time Domain Meteo-Ocean Modeling Approach

This paper presents a novel approach to repair modeling using a time domain Auto-Regressive model to represent meteo-ocean site conditions. The short term hourly correlations, medium term access windows of periods up to days and the annual distibution of site data are captured. In addition, seasonality is included. Correlation observed between wind and wave site can be incorporated if simultaneous data exists. Using this approach a time series for both significant wave height and mean wind speed is described. This allows MTTR to be implemented within the reliability simulation as a variable process, dependent on significant wave height. This approach automatically captures site characteristics including seasonality and allows for complex analysis using time dependent constaints such as working patterns to be implemented. A simple cost model for lost revenues determined by the concurrent simulated wind speed is also presented. A preliminary investigation of the influence of component reliability and access thresholds at various existing sites on availability is presented demonstrating the abiltiy of the modeling approach to offer new insights into offshore wind turbine operation and maintenance.

A one-dimensional numerical model for the momentum exchange in regenerative pumps

The regenerative pump is a rotor-dynamic turbomachine capable of developing high heads at low flow rates and low specific speeds. In spite of their low efficiency, usually less than 50 %, they have found a wide range of applications as compact single-stage pumps with other beneficial features. The potential of a modified regenerative pump design is presented for consideration of the performance improvements. In this paper the fluid dynamic behaviour of the novel design was predicted using a one-dimensional model developed by the authors. Unlike most one-dimensional models previously published for regenerative pumps, the momentum exchange is computed numerically. Previous one-dimensional models relied on experimental data and correction factors; the model presented in this paper demonstrates accurate prediction of the pump performance characteristics without the need for correction with experimental data. The validity of this approach is highlighted by the comparison of computed and measured results for two different regenerative pump standards. The pump performance is assessed numerically without the need of correction factors or other experimental data. This paper presents an approach for regenerative pumps using a physically valid geometry model and by resolving the circulatory velocity in peripheral direction.

Development of a Novel Wear Detection System for Wind Turbine Gearboxes

This paper presents a low-cost, inline, gearbox lubrication monitoring sensor. The purpose of the research was to develop a sensor that can analyze wear particles suspended in gearbox lubricant systems. Current inline sensor systems rely on methods that prevent significant morphological classification. The size and shape of the particles are often indicative of the type of wear that is occurring and is therefore significant in assessing the gearbox state. A demonstration sensor consisting of a webcam that uses an active pixel sensor combined with a rectangular cross section optically transparent acrylic pipe was developed. A rig that simulates a gearbox lubrication system was used to test the sensor. Images of wear particles suspended in the lubricant were captured in real time. Image analysis was then performed to distinguish particles from the lubricant medium. Object characteristics, such as area and major axis length, were used to determine shape parameters. It was found that the sensor could detect particles down to a major axis length of 125 μm. Classification was also demonstrated for four basic shapes: square, circular, rectangular and ellipsoidal. ellipsoidal, was also demonstrated.

Development of a robust structural health monitoring system for wind turbine foundations

The construction of onshore wind turbines has rapidly been increasing as the UK attempts to meet its renewable energy targets. As the UK’s future energy depends more on wind farms, safety and security are critical to the success of this renewable energy source. Structural integrity is a critical element of this security of supply. With the stochastic nature of the load regime a bespoke low cost structural health monitoring system is required to monitor integrity. This paper presents an assessment of ‘embedded can’ style foundation failure modes in large onshore wind turbines and proposes a novel condition based monitoring solution to aid in early warning of failure.

Development of a regenerative pump impeller using rapid manufacturing techniques

Purpose – The purpose of this paper is to present a method of rapid prototyping (RP) used in the development of a regenerative pump impeller. RP technology was used to create complex impeller blade profiles for testing as part of a regenerative pump optimisation process. Regenerative pumps are the subject of increased interest in industry.Design/methodology/approach – Ten modified impeller blade profiles, relative to the standard radial configuration, were evaluated with the use of computational fluid dynamics (CFD) and experimental testing. Prototype impellers were needed for experimental validation of the CFD results. The manufacture of the complex blade profiles using conventional milling techniques is a considerable challenge for skilled machinists.Findings – The complexity of the modified blade profiles would normally necessitate the use of expensive computer numerically controlled machining with five‐axis capability. With an impeller less than 75 mm in diameter with a maximum blade thickness of 1.3 ...

Detailed State of the Art Review for the Different On-Line/In-Line Oil Analysis Techniques in Context of Wind Turbine Gearboxes

The main driver behind developing advanced condition monitoring (CM) systems for the wind energy industry is the delivery of improved asset management regarding the operation and maintenance of the gearbox and other wind turbine components and systems. Current gearbox CM systems mainly detect faults by identifying ferrous materials, water and air within oil by changes in certain properties such as electrical fields. In order to detect oil degradation and identify particles, more advanced devices are required so allow a better maintenance regime to be established. Current technologies available specifically for this purpose include Fourier Transform Infrared (FTIR) spectroscopy and ferrography. There are also several technologies that have not yet been or have been recently applied to CM problems. After reviewing the current state of the art, it is recommended that a combination of sensors would be used that analyse different characteristics of the oil. The information individually would not be highly accurate but combined, it is fully expected that greater accuracy can be obtained. The technologies that are suitable in terms of cost, size, accuracy and development are online ferrography, selective fluorescence spectroscopy, scattering measurements, FTIR, photoacoustic spectroscopy and solid state viscometers.Copyright

Numerical and experimental design study of a regenerative pump

This paper presents the use of a commercial CFD code to simulate the flow-field within the regenerative pump and compare the CFD results with new experimental data. Regenerative pumps are the subject of increased interest in industry as these pumps are low cost, low specific speed, compact and able to deliver high heads with stable performance characteristics. The complex flow-field within the regenerative pump represents a considerable challenge to detailed mathematical modelling. This paper also presents a novel rapid manufacturing process used to consider the effect of impeller geometry changes on the pump efficiency. Ten modified impeller blade profiles, relative to a standard radial configuration, were evaluated. The CFD performance results demonstrate reasonable agreement with the experimental tests. The CFD results also demonstrate that it is possible to represent the helical flow field for the pump which has been witnessed only in experimental flow visualisation until now. The ability to use CFD modelling in conjunction with rapid manufacturing techniques has meant that more complex impeller geometry configurations can now be assessed with better understanding of the flow-field and resulting efficiency.