风电可靠性分析培训教材_图文

1、Wind Turbine Failure Rate Workshop 风力发电机组故障 Beijing 2009-10-22 1 Experience you can trust. Introduction介绍 On 22nd of October 2009 Vouching Technical Inspections Co., Ltd. and KEMA jointly organised a one day workshop on the reliability and availibility of windturbines in China. The title of the work

2、shop was Failure Rate Analysis. 2009年10月22日，华信技术检验公司和KEMA公司联合举办了一天针对中国风力发电机可靠 性和可用性研究的会议，主题为：故障率分析。 The program covered the following topics包括以下内容: Rates and reason 故障率和原因 Measures for improvement 改进的测量 Systematic ways to collect reliability data 用系统的方法收集可靠性数据 Quality Control 质量控制 This workshop was

3、organised in cooperation with同时我们得到了一下企业的帮助: China Electrical Equipment Industrial Association中国电器工业协会 National Technology Committee of standardization for Large Electrical Generator国家大型发电 机技术标准委员 Xiangtan Electric Traction Equipment Research Institute湘潭电机牵引设备研究所 This document bundles all presentati

4、ons that has been presented by KEMA during this day. 本文件包含KEMA提供的所有演讲内容 2 Content 内容 Rates and reasons 故障率和原因 Measures for improvement 改进的测量 Systematic ways to collect reliability data 用系统的方法收集可靠性数据 Quality control 质量控制 3 Wind turbines failures.风力发电机组故障 Recent wind turbine developments 近来风力发电机组的发展 D

5、efinitions 定义 Types of failures 故障种类 Failure frequency and downtime 故障频率及停机时间 Causes 原因 4 Wind turbine develop fast since 1980. 风力发电机组自1980年起发展迅速 130 m Ø 12 m Ø 1980 2009 5 Recent wind turbine power development slows down.近来风力发电机组能力发展变缓 10000 风力发电机组发电能力（千瓦） Wind turbine power kW 1000 Reali

6、sation Prognosed 实现 预测 100 10 1980 1985 1990 1995 2000 2005 2010 2015 2020 6 Components of a wind turbine. 风力发电机组的组成 齿端距 低速轴 轮毂 齿轮箱 发电机 风向 控制器 制动 风速计 偏航驱动机构 机舱 叶片 偏航马达 塔架 高速轴 8 风向标 Windturbine with gearbox. 带有齿轮箱的风力发电机组 9 Direct-Drive (gearless windturbine. 直驱式（不带齿轮箱）的风力发电机组 10 11Turbine technologye

7、volves. 风力发电机组技术演变在新安装的风力发电机组中所占比例基础丹麦技术高级丹麦技术直驱式标准变速式其它技术 12Corrective maintenance cost as a function of time 故障维修费用故障检修费用（欧元/千瓦）机组年限（年数）机组主的故障检修责任延期服务合同保修期Source: ECN 13Experience is important.经验至关重要平均年度故障率运作年限投入生产年限Source: ISETStatistics for wind turbine failures. 15Failure statistics over wholes

8、urvey period. 在调查全过程中的故障数据统计Source: ISETMany short events, a few requirelong repairs.许多短期事件，小部分需要较长时间维修.故障所占比例年度停机时间所占比例停机时间（天数） Overview of failurecategories. 故障种类概观故障所占比例年度停机时间所占比例停机时间（天数）电力控制感应器液压偏航系统叶片基础发电机齿轮箱动力传动系统支持及供给 Failures and repairtime per category.每个种类的故障和维修时间. 年度故障频次每次故障电力系统电子控制感应器液压系

9、统偏航系统轮毂机械制动叶片齿轮箱发电机支持与供给动力传动系统Failure data turbines > 1 MW.故障数据（机组1MW Number of failuresdepend on wind speed. 依据风速的故障数量.所有WMEP 测量数字的日均风速日故障数量动力传动系统叶片电动控制其它部件 Failures coincide with high wind season.与强风季节吻合的故障 月份风能指标故障率 Failure rates increase with turbine size.故障率随机组体积而增加.故障率（机组故障/年度）LWK 平均故障率：199

10、3-2004年第一族，小型第二组，中型第三组，大型 Changes in failuretypes. 故障种类的变化基础丹麦技术高级丹麦技术标准变速式直驱式年度故障频率电动系统电子控制感应器液压系统偏航系统轮毂机械制动叶片发电机齿轮箱动力传动系支持与供给Conclusions on failures. 故障结论1. Experience is important to reducefailures 经验对降低故障率至关重要2.Small number of largefailures with complicated repairs 需要复杂维修的大型故障发生率较低3.Numerous sma

11、ll events that require attention 需要关注的小型故障非常多4.Large windturbines withmore complex technicalconcepts have higherfailure rates 技术复杂的大型风力发电机组具有更高的故障率5. High wind speed (seasons correlatewith failures 强风速（季节）对应故障发生 Windturbine safety& structuraldamage. 风力发电机组的安全与结构损坏Wind turbines are designedto bes

12、afe under all conditions风力发电机组的设计应在所有条件下保持安全性Design criteria设计标准Independent safetysystems独立的安全系统However sometimes wind turbines fail但有时风力机组出现故障Wind conditionsoutside design envelope出现于设计方案之外的风力情况Failure safety system 故障安全系统Mechanical failure 机械故障External factors (lightning外界因素（雷电） Crash of wind turb

13、ine mast.风力发电机组塔架的倒塌 Rotor bladefailure 叶片故障. Rotor failure.轮毂故障 Failure rates and consequences.故障率及后果。 Personal risk (risk thatperson gets hit. 个人危险（人身伤害） Personal risk contours个人危险等高线10-6contour: hubheight + 0.5 rotor diameter塔基高度+0.5轮毂直径10-5contour: 0.5 rotor diameter0.5轮毂直径Wind turbine in Denmar

14、k. 丹麦的风力发电机组 31 Source: SENTERNOVEM Content 内容 Rates and reasons 故障率和原因 Measures for improvement 改进的测量 Systematic ways to collect reliability data 用系统的方法收集可靠性数据 Quality control 质量控制 32 Wind energy develops fast in China 中国的风能发展迅猛 Goal is 100.000 MW wind energy installed in 2020 到2020年的风能装机容量的目标是100.

15、000 MW Developments both in onshore and offshore locations 内陆风力发电和海上风力发电都要发展 Between 20000 and 50000 wind turbines 风力发电机组的数量将达到20000至50000 Wind farms range from small to very large wind farms 风力发电场规模有小有大，不尽相同 Many new wind turbine manufacturers enter the market 许多新涌现的风力发电机组制造商将进入市场 33 Beijing 2009-1

16、0-22 Many players want improved reliability 众多参与者希望提高可靠性 Wind farm developers like high wind energy output 风电场的开发者希望风能大量输 出 Authorities like reliable energy supply 当局者希望获得可靠的能源供应 Manufacturers like less cost for repairs and warranty claims 机组制造商希望维修和售后服务 的成本更低 Beijing 2009-10-22 34 What do we mean b

17、y improved by better reliability and availability? 更高的可靠性和可用率将意味什么？ Decrease failure events 故障事件的降低 Decrease downtime 检修停工期的减少 Decrease cost of repairs 维修成本的降低 Make wind turbines better fit for the environment 风力发电机组更适合所在环境 Improve maintainability and serviceability 改进机组的可维护性和可用性 Beijing 2009-10-22

18、35 How can reliability be improved?如何改进可靠性？Improved design改进设计 Testing 测试Fit for the environment适应环境Maintenance strategy维护策略Condition monitoring监测状态Statistics 统计数据Quality Control质量控制 基于可靠性的设备维修Reliability based maintenance Technology analysis shows conceptweaknesses通过技术分析阐述概念上的缺陷 Reliability of subs

19、ystems子系统的可靠性 Redundancy and safetymeasures can improve reliability example冗余设计和安全措施可以提高可靠性的案例Wind vaneis criticalelement forwind turbine safety. Failurewill lead to a wind turbine shutdown风向标对风力发电机组的安全至关重要，如有故障将导致风力发电机的停工。Redundancy 冗余设计Annual failure rates of wind vanesis relativelyhigh风向标的年故障率相对较

20、高Modern wind turbines have 2 wind vanes, whichincreases overall reliability现代的风力发电机组都配有2个风向标，提高了机组整体的可靠性Safety measures 安全措施Wind vanefailures are dueto icing 由于冰冻导致的风向标失灵Failure rate can be lowered by heating通过加热可以降低事故率Design measuresto decrease downtime采取措施以减少检修停工期 Increasing maintainability 提高可维护性

21、Internal crane enabling exchange of largeparts 内部起重机可以交换大型组件Standardisation 标准化Strategic maintenance supplies 战略维修用料Early fault recognition 早期故障诊断SCADA system 数据采集与监视控制系统Monitoring efficiency 效率监测Condition monitoring 状态监测Self-maintaining systems 自维持系统 Four relevant failuretypes 四种相关的故障类型 Effective O

22、&M canlower failure rate and downtime有效的运营和维护能够降低故障率和停工检修时间 Corrective vs. Preventivemaintenance 纠正策略及预防策略 Maintenance optimization 维护策略的优化Corrective maintenance is appliedwhen a component fails当组件发生故障时，就要进行故障检修Preventive maintenance to prevent component fromfailing 预防性养护可以防止组件故障Cyclic aimed at

23、preventedunscheduled downtimes 周期性的养护旨在避免计划外的停机检修Condition based optimizes maintenance cost and availability基于状况的养护可以优化维护成本和提高可用性Reliability based uses experience data to optimizemaintenance 基于提高可靠性的养护就要使用经验数据来优化养护措施Remote access requires better maintenance planning 远程访问需要更好的维护计划Systematic data coll

24、ectionrequired系统数据采集很有必要 Service & Maintenance (S&M 服务与维修(S&M Cost per year about 1,5% of investment costs 每年大约占投资成本的1,5 % Cost Service & Maintenance during warranty period considerably lower 在保修期内，服务与维修成本相对低廉 Service offered by manufacturing (during warranty period or by special mai

25、ntenance companies 服务由制造商(在保修期内或特殊维护公司提供 Normally combination of Preventive and Corrective Maintenance 一般将预防性维护和故障维护结合起来 Blade maintenance by means of special Service and Maintenance Contract 叶片维修通过特殊服务和维修合同进行 Beijing 2009-10-22 46 Preventive maintenance 预防性维护 2x per year (1 tot 3 days per service 2

26、次/每年 (1-3天/每次 Limited cleaning局部清洗 Visual inspections视觉检测 Small repairs and modifications 小规模的维修和改造 Check and replace oil and grease 检查并且替换机油和润滑油 Check Control and safety systems 检查控制和安全系统 Check vital components and connections 检查关键组件和连接点 Beijing 2009-10-22 47 Corrective maintenance 纠错性维护 Dependent on number of failure event (on average 2x to 4x per year per wind turbine与故障次数无关(平均 2x - 4x /每年/ 每个风力发电机组 Notification by wind turbine/wind farm SCADA system, central control room or wind farm managerResponsetime 24 to 48 hours 由风力发电机组/风电场数据采集监控系统， 中央控制室或风电场经理发出通告