main bearing rca
TRANSCRIPT
© 2016 Sentient Science Corporation – Confidential & Proprietary
Main Bearing RCA
© 2016 Sentient Science Corporation – Confidential & Proprietary
Material Science Differentiation1. Asset Management for Operators 2. Computational Testing & Reconfiguration for Suppliers
☑ Life Extension☑ Root Causes☑ Predict Earlier
Key Industries Served
WIND ENERGY • 20,000 assets under contract globally
AEROSPACE• Rotorcraft, Fixed Wing, & Defense
• (15 Years of R&D)
RAIL• 1 Million km Global Railways
• Wheel Rail Interface
Sentient Science is a trusted third party enabling life extension of rotating equipment through a digital platform, connecting operators and suppliers through asset actions that lowers the cost of energy.
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Why Investigate Main Bearings?
3
High Risk:
Main bearing failure often
transfers thrust loads to the
gearbox, which can lead to
catastrophic damage in the
gearbox.
High Cost:
Main Bearing Replacement
ranges from $150K - $300K. In
extreme cases can cause
upwards of $500K.
Uncertainty:
Alerted of main bearing failure after
SCADA temperature alarms are
going off.
Supply Chain Control:
Lack of control in supply chain due
to no lead time for main bearing
failures, causing unexpected
downtime.
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Premature Failure in Main Bearings
Main Bearing Wear Model
Three Point Configuration
Spherical Roller Bearing
INNER RACE, OUTER RACE,
ROLLER
CAGE, GUIDE RINGS
High Radial load capacity
Accommodates misalignments
Require relatively high ratio of
radial to axial load
Increased sliding due to
Heathcote slip
Thrust Load
Bearing Design
Low RPM
Loss of Lubrication
Uneven Load Distribution
Surface Roughness
Lubricant Viscosity
High Pressure
High Sliding
Low Lambda
Low Lambda
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Failure Modes in Main Bearings
Main Bearing Wear Model
Wear on Inner Race
MicropittingMacropitting
SpallingAbrasive Damage Roller, Cage Crack
FAILURE PROGRESSION IN MAIN BEARINGS (manifests as early as 6 TO 10 YEARS)
Sentient’s Main Bearing Failure model identifies early manifestation of damage in Main Bearings and provides
recommendations to slow down damage progression, such that the Remaining Useful Life of the bearing can be extended
Asperity Plastic Deformation
Adhesive wear, Surface Fatigue
Wear Bands on Inner Race
Incubates in the vicinity of wear
bands
Cyclic shear stresses at
shallow depths below the
asperities
Loss of geometry due to
significant micropitting
High contact stresses, edge
loads
Debris dents the race and
rollers
Rapidly evolves and
accelerates damage
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Main Bearing Wear Model
DigitalClone Live Main Bearing Model Strategy
WIND LOAD MODEL BEARING DYNAMICS MODEL WEAR MODEL
SCADA data
Turbulence Intensity
Windspeed
Wind Direction
Loads on Main shaft
Bearing Configuration Geometry
Bearing Clearances
Material Elastic modulus
Main shaft RPM
Contact Pressure
Sliding Velocity
Material : Hardness, Elastic Modulus, Ultimate
Strength
Surface topography : 𝑅𝑞 , 𝑅𝑠𝑘, 𝑅𝑘𝑢, 𝛽𝑥, 𝛽𝑦Lubricant: Viscosity, PV Coeff
Main Bearing Risk Ranking [MTOD]
Critical locations
Life Extension Action
Wear Rate
Wear Coefficient
Inputs
Outputs
Local Contact Forces
Sliding velocities
Equivalent Radii
Overturning Moments
Thrust, Radial Load
© 2016 Sentient Science Corporation – Confidential & Proprietary
Learn More!
Sentient Presentation Schedule Wind Europe 2017
1. DigitalClone Live Product Update
2. Why Data Science Wont Lower the Cost of Energy
3. Reducing Costs with Digitalization
4. Duke Energy Case Study
5. Rewitec Additives to Extend Gearbox Life
6. Moventas XL Life Extension Program
7. How to Value Digitalization
8. Sentient in the China Wind Market
9. DigitalClone Bearing Product Release
10. Wind Loads Modeling
11. Drive Train Modeling
12. Data Fusion Materials Science & Data Science
Hello 7
Meet the team in the booth for further discussions