Drivetrain Components Reliability And Optimisation Forum

Drivetrain Component Reliability Forum And Optimisation Forum

Forum Day 1 - Tuesday 23 May 2017

Registration And Refreshments


Chair's Opening Remarks

Christian Fenselau,  Chief Specialist Test And Validation,  Vestas


Life-Cycle Cost Challenges From An Owner Operator’s Perspective

  • Taking into account failures of gearboxes and generators in early life

  • Cost relation to the capability of suppliers to manufacture gearboxes that are reliable

  • Forecast and budgets: when to upgrade, repair or replace?

  • Failure models and practical examples on minimising failures

  • Quality assurance and durability requirements

  • Refurbishment of drivetrain

    • What standards do we request to suppliers to push them on the 20+ years promise?

    • What kind of testing do we request?

Giacomo Barbieri,  Production Optimisation Manager,  ERG  Power Generation, Italy 



Condition Monitoring From An Asset Management Perspective 

  • Analysing developments and improvements in diagnosis and how these influence failure modes 
  • Predicting failures with confidence and in a timely manner to make prompt decisions on your fleet 
  • Real examples and case studies of cost savings through condition monitoring

Anthony Birchall, Senior CMS Engineer, RES Group


Networking Break And Morning Refreshments 


How To Identify The Main Sources Of Faults And Predict Those That Will Turn Into Failures

  • Failure analysis and turbine reliability performance

  • Preventing failures through periodic repair and testing techniques

  • Gearbox service technology and site access suitability

  • Managing failure control in order to reduce downtime

Adam Johs, Turbine Reliability Engineering Manager, EDPR North America


Practical Experience On How To Achieve Better Understanding Of Gearbox Failures And Improved Reliability

  • Best practises used to set up an internal condition monitoring centre

  • Addressing gearbox repair challenges and consequent necessity for fault detection

  • Quickly and efficiently detect and remedy faults, failures and fatigue quicker

  • Oil and lubrication solutions to improve reliability of gearboxes

Javier San-Miguel Armendariz, Strategy And Business Development Manager, CENER


Case Studies On Increased Reliability For Early Detection Of Planet Gear Faults

  1. Challenges in gearbox 1st stage fault detection
  2. Importance of lead time to maintenance and the factors that influence it
  3. Reliability improvement of 1st stage fault detection over the years
  4. Actual case studies
  5. Economic benefits of early and reliable detection and diagnostics of faults

Jonel Palou,  Diagnostic Engineer,  Brüel & Kjær Vibro


Networking Lunch 



Streamlining And Fine Tuning Your Predictive Maintenance Regime To Avoid Unexpected Costs

How many times have you heard colleagues and peers complaining about lack of knowledge and data sharing in the Wind industry? And, how many times did you all agree that the ultimate goal is to provide energy at affordable prices by bringing down O&M costs through preventative maintenance?

This session has been designed for audience participation and knowledge sharing with no excuses! Instead of slowly passing around a stick microphone, simply throw the soft catchbox to the first person in the room who’s meeting your eyes!

Delegates are encouraged to come along with ideas, comments and provocative questions for their peers. This is a self-moderated session so there won’t be such thing as hiding in corners!


Improving Performance Through Calculations And Loads Of Core Drivetrain Components

  • Calculations based on turbine production and how much lifetime has been consumed

  • Developing a service to calculate how long their turbines have left to operate and what can be done to extend their working lives

  • Looking specifically at the gearbox and bearing in order to calculate the earliest point of cracks and problems occurring in components

  • Simulating the outcome of different solutions — such as replacing a part, re-rating the turbine through operations, or making an oil change

  • Giving the owner valuable information on which they can they can base their decision


Emulation And Measurement Of Wind Turbine Power Converter Junction Temperature

  • Background to why we are doing the work (failure rates of power converters in wind turbines)
  • Outline of experimental work into measuring the junction temperature using IR sensors
  • Work into emulation of wind turbine operational profiles in the laboratory
  • Outline of our collaboration with a power electronics testing company on this project and future ideas

Christopher Smith, Postgraduate Researcher, Durham University


Networking Break And Afternoon Refreshments

The OEM “Servitisation” Disruption And Asset Management Strategies


OEM’s Case Study: From Turbine Manufacturer To Service Provider

  • The change in business model and revenue streams to ensure a better service to owner operators

  • The “availability” phenomenon and how this is going to impact O&M costs  

  • Change of revenue streams and effect on the service providers’ market

Reducing Downtime Through Effective Logistics And Spare Parts Service Optimisation

  • Root cause analysis and service optimisation

  • Avoiding part exchange delays due to high speed wind and uneasy atmospheric conditions

  • Effectively disassembling components on site by building on technicians’ knowledge

  • How to best choose your service provider by looking at

    • track record

    • range of brands serviced

    • geographical expertise


The Role Of Asset Management In Reducing O&M Costs Whilst Maximizing Profitability And Prolonging A Fleet’s Lifetime 

  • Extend lead time by planning ahead

  • Optimising spare parts replacement  

  • Avoiding failures due to mistakes during installation, design, wear out, damage or fatigue

  • Understand how extended lead-time translates to substantial savings

  • What information do you need from your drivetrain to make the right choices for your fleet?

Francesco Vanni, Senior Engineer - Asset Integrity And Performance , DNV GL 


Speed Networking

Realising the importance of connecting with your peers, we organised a moderated networking session where delegates are prompted to meet others in brief 3-minute rounds. The moderator will be keeping track of time and announcing participants when to switch partners.

Make sure you bring lots of business cards along with you!


Chair’s Closing Remarks


Close Of Day One

Forum Day 2 - Wednesday 24 May 2017

Registration And Morning Refreshments


Chair's Welcome And Opening Remarks

Christian Fenselau, Chief Specialist Test And Validation, Vestas

New Design Advancements And Manufacturing Challenges


Hybrid Designs: When Gearboxes And Generators Become One

  • Meeting the industry's pressing need for greater reliability

  • Combining a simplified medium-speed gearbox with a mid-speed permanent magnet generator

  • Simplifying the power train and improve performance and reliability

  • Reaching the goal of having a simpler and more reliable gearbox, with a generator of comparable size

Jan-Henrik Jansen, Head Of Blade And Gearbox Service, Nordex 


New vs. Older Turbine Designs: Does Technology Innovation Mean Improvement But Also Different Challenges?

  • Future gearbox designs and hybrids - fine tuning the manufacturing process

  • Comparing the vibration level between old and new designs to assess failure mode

  • How are new gearbox designs going to improve lifetime and power production compared to older turbines?  

  • New designs: Is there going to be a knowledge gap to deal with fault prevention?  


Testing And Field Verification Measures Of Components, Sensors And Upgrades  

  • Failure mechanism of gearboxes: where do they come from? How to prevent them long term

  • Going back to manufacturing to prevent cracks and defects

  • New designs - relying on the information OEMs provide and creating a trustworthy relationship

  • Testing components and sensors to validate responsiveness to different climates and atmospheric conditions

Pieter Jan Jordaens, Business Development Manager, OWI-Lab 


Networking Break And Morning Refreshments


OEM’s Perspective On Direct Drive Technology Developments

  • Simplifying the nacelle systems in order to increase reliability, efficiency and avoid gearbox issues

  • Addressing challenges in producing technology that is lighter or more cost-effective than the conventional geared drive trains

  • Where do direct drivetrain place themselves in the market today?

Steffan Hansen, H ead Of Technology, Power Converter And Generator, Siemens 


Full Scale Main Shaft Fatigue Testing 

  • Test plan development 
  • Operative challenges
  • Insight on found results

Hans Kyling, Research Associate, Division Wind Turbine And System Technology, Fraunhofer IWES 


Networking Lunch 



Big Data And Field Results To Extend Turbine Longevity

  • Field data enabled design is based on in real life operating conditions
  • Loads are determined from the operational fleet
  • Main failure modes are learned from maintenance data

Dr. Jan Helsen, Coordinator Big Data , Owi-lab/VUB


The Internet Of Things (IoT): Bridging The Gap Between Wind Farm Location And Remote Access

  • Avoiding failures in remote locations which result in interrupted power generation and decreased productivity

  • Enhancing a wind farm’s profit margins against fluctuating energy prices

  • Giving wind farm operators control to monitor and regulate a turbine’s operation

  • Accessing information and data from machines, sensors, and controllers connected to the Internet.

  • Collect, exchange, monitor, analyse, and act on information to intelligently make changes with little to no human intervention


Networking Break And Afternoon Refreshments

Moving Towards The End Of A Turbine’s Lifetime


An Owner Operator's Insight On Turbines Out Of Warranty And Asset Reliability Models

  • What is a owner operator’s approach towards turbines 20-23 years old?
  • How to choose when to repair, replace or decommission
  • Assessing which components you need solutions for and source a cost-effective service provider
  • How to best choose your service provider by looking at

o track record

o range of brands serviced

o geographical expertise

Michael Davies, Senior Operations Engineer, RWE Innogy


The Industry’s Headache: Retrofitting Or Replacing?

  • Latest developments on the drivetrain for new wind turbines and option modifications for older ones

  • Why replacing when you can optimise?

  • Having the ultimate goal in mind: extending the lifetime and acting upon it through repowering or replacing

  • Non-European suppliers: do they understand the product and wind sufficiently to be reliable supplier

  • The remaining use of lifetime - providing a useful tool to predict better component replacement and optimise logistics for main bearings

  • When does it become too late to retrofit?

  • Retrofit and servicing - how to choose components and systems that add value to your turbines

  • How to replace components to minimise problems and maximise performance

  • How to analyse the impact of retrofitting on turbine performance


Michael Davies, Senior Operations Engineer, RWE Innogy

Michael Wilkinson, Service Line Leader Asset Operations & Management, DNV GL

Marco Cannarozzo,  Production Optimisation Manager,  ERG Power Generation, Italy

Moderator: Christian Fenselau, Chief Specialist Test And Validation, Vestas


Chair's Closing Remarks


Close Of Forum