Operation and maintenance technology of wind turbine generators
2026-04-06 06:39:19··#1
I. Operation The control system of a wind turbine generator set uses an industrial microprocessor for control, typically with multiple CPUs running in parallel. It has strong anti-interference capabilities and can be connected to a computer via communication lines for remote control, greatly reducing the workload. Therefore, wind turbine operation mainly involves remote fault diagnosis, operational data statistical analysis, and fault cause analysis. 1. Remote Fault Diagnosis Most wind turbine faults can be remotely and automatically reset. Wind turbine operation is closely related to grid quality. For bidirectional protection, wind turbines are equipped with multiple protection faults, such as high/low grid voltage and high/low grid frequency, which can be automatically reset. Due to the uncontrollable nature of wind energy, the over-wind speed limit can also be automatically reset. Temperature limits can also be automatically reset, such as high generator temperature, high/low gearbox temperature, and low ambient temperature. Overload faults of the wind turbine can also be automatically reset. Besides automatic reset faults, other remote reset control faults can be caused by the following: (1) false alarms from the wind turbine controller; (2) malfunctions of various detection sensors; (3) the controller considers the wind turbine operation unreliable. 2. Operational Data Statistical Analysis Detailed statistical analysis of the operation of wind farm equipment is an important part of wind farm management. Through statistical analysis of operational data, the operation and maintenance work can be assessed and quantified, and effective theoretical basis can be provided for wind farm design, wind resource assessment, and equipment selection. The monthly power generation statistics report is one of the important contents of the operation work, and its accuracy and reliability are directly linked to economic benefits. Its main contents include: monthly power generation of the wind turbine, power consumption of the farm, normal operating time of the wind turbine equipment, failure time, standard utilization hours, power grid outage, failure time, etc. The statistical analysis of the power curve data of the wind turbine can provide practical basis for improving the output of the wind turbine and improving the wind energy utilization rate. For example, after analyzing the power curves of domestically produced wind turbines, we adjusted the installation angles of the latter three turbines, reducing output in high-wind-speed areas, increasing utilization in low-wind-speed areas, reducing over-generation and generator overheating faults, and improving equipment availability. Through statistical analysis of wind condition data, we grasped the seasonal output patterns of various types of wind turbines, and based on this, we can develop a reasonable schedule for regular maintenance to reduce wind resource waste. 3. Fault Cause Analysis Through in-depth analysis of various wind turbine faults, we can reduce troubleshooting time or prevent the occurrence of frequent faults, reduce downtime, and improve equipment integrity and availability. For example, in analyzing the overload fault of the yaw motor of a 150kW wind turbine, we found that there are several reasons for this fault. Mechanically, wear on the motor output shaft and keyway can cause overload; changes in the yaw slipper clearance can also cause overload; and broken teeth on the yaw gear can also cause yaw motor overload. Electrically, overload can be caused by damage to the soft yaw module, soft yaw trigger board, yaw contactor, or malfunction of the yaw electromagnetic brake. Similarly, in analyzing the failure of the control voltage disappearance in the Jacobs series wind turbine, we used an elimination experiment method. We modified the circuit of the measurement signal components in the safety chain that could potentially cause the fault using signal relays and shorting wires. Ultimately, we located the cause of the fault to the setting of the overspeed pressure switch, reducing the frequency of this fault, improving equipment utilization, reducing the frequency of brake pad replacements, and lowering operating costs. II. Maintenance Wind turbines are comprehensive products integrating electrical, mechanical, and aerodynamic disciplines. All parts are closely interconnected and interdependent. The quality of wind turbine maintenance directly affects the amount of electricity generated and the level of economic benefits. The performance of the wind turbine itself also needs to be maintained through maintenance and repair. Timely and effective maintenance can identify potential faults, reduce the occurrence of malfunctions, and improve turbine efficiency. Wind turbine maintenance can be divided into two types: periodic inspection and daily troubleshooting. 1. Periodic Inspection and Maintenance of Wind Turbines Regular maintenance keeps the equipment in optimal condition and extends the service life of the wind turbine. The main contents of periodic inspection and maintenance include: checking the bolt torque of the wind turbine connecting parts (including electrical connections), lubrication of various transmission components, and functional testing. During normal operation, the bolts of the connecting parts are subjected to various vibrations and forces over a long period of time, making them prone to loosening. To prevent uneven stress and shearing of bolts due to loosening, we must regularly check the bolt torque. When the ambient temperature is below -5℃, the torque should be reduced to 80% of the rated torque before tightening, and the check should be repeated when the temperature rises above -5℃. We generally schedule bolt tightening checks during the windless or low-wind summer months to avoid the peak wind turbine output season. Wind turbine lubrication systems primarily use two methods: thin oil lubrication (or mineral oil lubrication) and dry oil lubrication (or grease lubrication). The wind turbine gearbox and yaw reduction gearbox use thin oil lubrication. Maintenance involves replenishing the oil and sampling for testing. If the test results indicate the lubricating oil is unusable, it must be replaced. Dry oil lubrication is used for components such as generator bearings, yaw bearings, and yaw gears. These components are prone to deterioration due to high operating temperatures, leading to bearing wear. Regular maintenance requires replenishing the oil each time. Furthermore, the amount of oil added to the generator bearings must be strictly according to the requirements; excessive amounts can force into the motor windings and burn out the motor. Regular maintenance functional tests include overspeed testing, emergency stop testing, hydraulic system component setpoint testing, vibration switch testing, and cable twist switch testing. Routine tests can also be performed on the controller's limit values. In addition to the three main items mentioned above, regular maintenance also includes checking the hydraulic oil level, whether each sensor is damaged, whether the sensor power supply is working reliably, and the wear of the brake pads and discs. 2. Routine Troubleshooting and Maintenance During operation, the fan may experience some malfunctions that require on-site handling. This allows us to perform routine maintenance at the same time. First, carefully observe whether the safety platform and ladder inside the fan are secure, whether there are any loose connecting bolts, whether there is a burnt smell in the control cabinet, whether the cables are displaced, whether the clamps are loose, whether the cable twist sensor pull ring is worn or broken, whether the lubricant for the yaw gear is dry and deteriorated, whether the yaw gearbox, hydraulic oil, and gearbox oil level are normal, whether the pressure gauges in the hydraulic station are normal, whether there is wear between rotating parts, whether there are any leaks at the oil pipe joints, and whether the gear oil and hydraulic oil filter indicators are in the normal position, etc. Secondly, listen carefully. Check the control cabinet for any discharge sounds. Such sounds may indicate loose wiring terminals or poor contact, requiring careful inspection. Listen for normal yaw sounds, dry grinding noises, abnormal noises from the generator bearings, gearbox, brake disc and brake pads, and normal blade shearing sounds. Thirdly, clean the work area thoroughly, wiping clean all components and pipe joints of the hydraulic station for future leak detection. While these routine maintenance items are not exhaustive, careful attention each time will prevent potential malfunctions and improve equipment availability and uptime. To effectively operate and maintain wind turbine generators, it's essential to conduct in-depth research and study of relevant theoretical knowledge, meticulously maintain and archive maintenance records, regularly inventory spare parts, and thoroughly analyze common wind turbine failures, striving for effective prevention. Only by preventing problems before they occur can we achieve the highest level of operation and maintenance.