Posters
Come meet the poster presenters to ask them questions and discuss their work
We would like to invite you to come and see the posters at our upcoming conference. The posters will showcase a diverse range of research topics, and will give delegates an opportunity to engage with the authors and learn more about their work. Whether you are a seasoned researcher or simply curious about the latest developments in your field, we believe that the posters will offer something of interest to everyone. So please join us at the conference and take advantage of this opportunity to learn and engage with your peers in industry and the academic community.
PO206: Early detection of recurring IMS bearing defect patterns for fleet-wide asset management and lifetime extension
Emerson Lima, Manager of Condition Analysis Center, AQTech Power Prognostics
Abstract
Condition monitoring systems (CMS) are essential to protect wind turbine fleets from drivetrain failures. In a 100-unit, 2 MW wind farm, CMS identified recurring inner race fractures in the downwind bearing of the intermediate-speed shaft (IMS). Manual vibration analysis first confirmed three defective turbines, supported by borescope inspections. Applying an AI approach across the farm revealed that a total of 15 turbines were affected by the same failure mode, turning an isolated issue into a fleet-wide challenge. Initially, the only feasible option appeared to be the replacement of 15 gearboxes, since bearing substitution was considered extremely difficult at nacelle level. CMS, however, enabled early detection and precise monitoring of defect progression. Vibration peaks rose sharply while RMS remained stable, a clear signature of impact-type defects. This stability allowed operators to safely limit the affected turbines to 50% load, keeping vibrations under control and maintaining partial generation. The controlled operation bought valuable time to research alternatives and contract a specialized service provider capable of performing an uptower bearing replacement. After approximately 10 months, this solution was successfully implemented, restoring turbines to normal operation without gearbox removal. By avoiding 15 gearbox replacements, the intervention reduced costs from US$ 7.3 million to US$ 216,000—achieving 97% savings—while ensuring fleet availability and minimizing downtime.
No recording available for this poster.
