Wind turbines: how to increase the reliability of this asset

Wind turbine: learn about its main components and how to monitor this asset

According to the National Electricity System Operator (ONS), wind power accounts for 10.9% of the Brazilian electricity matrix and is expected to reach 13.6% by 2025. This growth is linked to the pursuit of increased clean energy production, in order to honor the commitment made at the Climate Summit to bring forward climate neutrality from 2060 to 2050.

Although it is a clean energy and its use is expanding, it is essential to seek to maximize productivity. To this end, the energy industry must find ways to guarantee the reliability, availability and maintainability of its assets.

A wind turbine is a piece of equipment that harnesses the kinetic energy of the wind to generate electricity. Here we listed the amain components of this asset and actions to increase equipment availability by identifying the main associated faults, such as overheating, electrical, dynamic and mechanical effects.

Wind turbine components 

Component	Possible faults	Identification method
Blades  They are responsible for capturing the kinetic energy of the wind and transferring it to the rotor.	Unbalance	Vibration and temperature monitoring
Rotor  It transfers the movement of the blades to the main shaft, which can be horizontal or vertical.	Unbalance Lubrication problems Bearing defects Mechanical problems
Transmission box  It increases the speed coming from the rotor by up to 120X, to a speed at which the generator can operate.	Looseness Lubrication problems Gear defects
Generator  Responsible for converting the mechanical energy of shaft rotation into electrical energy.	Overheating Bad contact Lubrication problems Bearing defects	Current and voltage monitoring Vibration and temperature monitoring
Main rolling bearing  It supports the low-speed rotating shaft and reduces friction between moving parts.	Looseness Lubrication problems Bearing defects	Vibration and temperature monitoring
Nacelle  It houses the entire generator mechanism, such as: gearbox, brakes, clutch, bearings, electronic control, hydraulics, etc.	Seal damage Wear	Sensitive inspection
Tower  It supports the rest of the equipment.	Corrosion Wear

How to increase the reliability of wind turbines

One of the main ways to increase wind turbine reliability is through the efficient management of these assets, which includes maintenance planning and tools for monitoring possible failure indicators.

Maintenance planning must indicate the risk of machine malfunction, avoiding unplanned downtime. There are various parameters that can be measured to evaluate the operation, but the ones that provide the most assertiveness for a large number of assets are: vibration, temperature, current and voltage.

Vibration and temperature analysis 

Vibration analysis is one of the predictive maintenance techniques that uses vibration measurement to monitor the health of machinery.

To measure vibration and temperature continuously, sensors are attached to the machine. By collecting this data, it is possible to check for anomalies that are not visible at first glance. And, at the same time, without interrupting the use of the machine. Each component has a characteristic vibration signature, which, when it deviates from the standard, indicates a failure mode.

Similarly, temperature monitoring makes it possible to track variations that could indicate overheating as a result of a fault.

Read also: Vibration analysis in industrial machines: main gains (dynamox.net)

Current and voltage analysis 

Current and voltage data help to identify possible faults, as well as indicate a worsening in the operating condition. This information makes it possible to identify problems related to supply voltages, insulation or connection problems, load variation, among others.

To acquire this information, boards or sensors attached to the electrical equipment can be used, maintaining continuous data collection. This type of monitoring makes it possible to track down incipient faults in specific parts of the electric motor drive. It also gives a clear indication of how quickly anomalies are evolving over time.

Here are some examples: Electric motors: 5 cases of condition analysis (dynamox.net) 

Sensitive analysis

Sensitive inspection is a technique in which the analyst uses human senses to evaluate the equipment. However, there is also instrumented sensing, which consists of using devices and instruments to analyze signals that cannot normally be perceived by the human senses.

It is used to detect problems such as rust, oil leaks, the presence of abnormal odors, plate thickness, worn out screws, etc. Sensitive inspection is usually one of the first steps in implementing a maintenance plan that includes predictive strategies in addition to corrective and preventive ones.  

Read also: Sensitive inspection in maintenance (dynamox.net) 

Strategic maintenance management in turbines

For maintenance to become strategic, it is necessary to have organized data to support decision-making. In other words, use predictive techniques to avoid the unnecessary replacement of components, as well as eliminating unplanned downtime.

Acquiring data through sensors is one of the best ways of obtaining accurate information. These analyses help the manager to know when it is necessary to intervene or even to define when the component should be replaced. Continuous information allows for assertive planning, helping to ensure the availability and reliability of the wind farm as a whole.