Condition Monitoring for 100+ Wind Farms, Precision Alerts Ensure Stable Operation of Aging Assets

Case Time:

2012 - Present (12+ Years)

Client Background:

China Huadian Corporation Ltd. is one of China's five state-owned power generation giants established during the power sector reform. As an extra-large central enterprise supervised by SASAC, it is authorized by the State Council as a pilot institution for state-invested and state-controlled companies.

Client Requirements & Solutions

Retrofitting for Data Integration, Comprehensive Turbine Health Management

Real-time Monitoring of Critical Components & Enhanced Auxiliary System Data Utilization:

The client sought to deploy CMS systems for 1.5MW/2.0MW turbines operating over 5 years, enabling real-time monitoring of major components and comprehensive operational visibility.

Ronds' Solution:

For legacy wind farms: Provided backward-compatible hardware replacements and lifetime software upgrade support for auxiliary systems aged 5+ years

Integrated "Wind Farm-Regional-Control Center" data channels in collaboration with Guodian Nanjing Automation Co., Ltd.

Predictive Maintenance for Key Components:

Customized monitoring solutions for blades, towers, bolts, etc., with condition assessment and predictive analytics applied to high-capacity multi-MW turbines like:

Large-scale projects (Hinggan League)、Offshore installations (Yuhuan City in Taizhou)

Application Value

Wind Farms Monitored: 150+

Turbines Covered: 5400+

Health Reports Generated: 4000+

Closed-Loop Cases Resolved: 800+

Multi-Region Retrofits Unify Group-Wide Data Flow:

Upgraded systems across Xinjiang, Ningxia, Shaanxi, Gansu, and Yunnan, replacing defunct CMS hardware at reduced costs while establishing integrated data links with Huadian Electric Power Research Institute CO., Ltd..

Enabling Smart Wind Farm Development:

Through component-level data aggregation and predictive analysis, Ronds supports Huadian's intelligent wind farm initiative, pioneering centralized monitoring and diagnostic management models for renewable assets.

Success Cases

Gansu Huadian Guazhou Wind Power Co., Ltd. 48#

1. Equipment Information
Equipment Type: Doubly-fed
Rated speed: 1800rpm
Measuring point associated with this case: Gearbox first-stage planetary gear 2H
2. Alarm and Analysis Process
Equipment Alarm Events:
2.1 Analysis Process
2.1.1 Explanation of Trends and Indicator Parameters
A sudden high point of acceleration vibration at the 2H measuring point of the first-stage internal ring gear.
48#/Gearbox First Stage Planetary Gear 2H/256k Acceleration Waveform (0.1-2000)_Multi-parameter Analysis
The total speed value of the first-stage ring gear 2H measuring point shows a synchronous increase.
48#/Gearbox First-Stage Planetary Gear 2H/16k Speed Waveform (10-1000)_Trend Analysis
2.1.2 Time-domain, frequency-domain, envelope demodulation, and other evidence explanations
Impact characteristics of the first-stage internal ring gear are visible in the acceleration time-domain waveform.
48#/Gearbox First-Stage Planetary Gear 2H/256k Acceleration Waveform (0.1-2000)_Time-Domain Waveform
Disturbances in the first-stage ring gear are visible in the speed waveform, possibly related to changes in the stiffness of the first-stage ring gear, such as cracks in the gear.
48#/Gearbox First-Stage Planetary Gear 2H/16k Speed Waveform (10-1000)_Time-Domain Waveform
The spectrum of the first-stage meshing band has rich sidebands of the internal ring gear defect frequency.
48#/Gearbox First-Stage Planetary Gear 2H/256k Acceleration Waveform (0.1-2000)_Spectrum Analysis
3. Diagnosis Conclusion and Recommendations
3.1 Diagnostic Conclusion
2022-05-07 03:37 Diagnostic conclusion pushed: The first-stage internal ring gear has sudden damage, the internal ring gear has spalling or broken teeth, and the gearbox has the risk of jamming if it runs for a long time. (Notified by phone at 3:30)
3.2 Recommendations
It is necessary to arrange for inspection of the actual situation of the equipment on site as soon as possible, and the equipment has the risk of failure if it runs in this state for a long time. 1. If there are conditions for shutdown, shutdown can be arranged first; 2. Check the damage of the first-stage internal ring gear of the gearbox.
4. On-site Maintenance Process
1. 2022-05-08 13:42 Zhan Gong from the site reported that the endoscope inspection showed pitting on the tooth surface of the first-stage ring gear, but no obvious damage was found.
2. 2022-09-14 10:50 The site reported that the box body at the first-stage ring gear position of the gearbox was cracked and leaking oil. It is now shut down.
5. On-site Maintenance Photos
Images confirm liner plate wear
Endoscope report attached drawing 1
Endoscope report attached drawing 2
Endoscope report attached drawing 3
6. Post-Maintenance Verification
The unit has not been started after the maintenance.
7.Customer Feedback Form
None
8.Monitoring Fault Range
The timely and effective collection of equipment operating status data (vibration, temperature) is restricted by network smoothness and data transmission time, and the interference of equipment attributes and production technology should also be considered. At the same time, the analysis and diagnosis of equipment status are based on changes in the vibration effects caused by rotating moving parts failures. Therefore, the condition monitoring system cannot guarantee monitoring of all types of failures. This monitoring system is configured according to the measurement point scheme recommended by Party B, and the monitoring fault range and description are as follows:
9.Precautions
1. If the client of this report cannot provide basic unit parameters (such as: unit transmission chain diagram, gearbox structure diagram, gearbox gear number, etc., related bearing models and brands), it will affect the accuracy of the analysis and diagnosis;
2. This report is the analysis, diagnosis, and maintenance opinions of the unit by Rongzhi professional technicians, and is for reference only. The specific maintenance measures need to be determined by the client;
3. This report is not to be used as proof for any claims, lawsuits, etc.;
4. The client is obliged to keep the analysis report confidential, and shall not provide this report to a third party, print it into other promotional materials, or publish it on the Internet or other public information platforms without the written permission of the trustee.

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China Huadian Shangyi Wang Yueliang Wind Power Wind Turbine No. 10

1. Equipment Information
Equipment Type: Doubly-fed
Rated speed: 1800rpm
Measuring point associated with this case: Gearbox high-speed shaft 5H
2. Alarm and Analysis Process
Equipment alarm event:
2.1 Analysis Process
2.1.1 Explanation of Trends and Indicator Parameters
The acceleration of the high-speed stage of the gearbox and the adjacent measuring points continues to rise.
Wind Turbine No. 10 / Gearbox High-Speed Shaft 5H/128k Acceleration Waveform (0.1-20000)_Equipment Multi-Trend
2.1.2 Time-domain, frequency-domain, envelope demodulation, and other evidence explanations
Obvious impacts are visible in the time domain waveform, with clipping occurring in the high-speed stage time domain waveform.
Wind Turbine No. 10 / Gearbox High-Speed Shaft 5H/128k Acceleration Waveform (0.1-20000)_Time Domain Waveform
The background noise energy in the high-frequency range of the spectrum is significantly higher.
No. 10 Wind Turbine/Gearbox High-Speed Shaft 5H/128k Acceleration Waveform (0.1-20000)_Spectrum Analysis
In the spectrum of the early stage of the fault, the bearing outer ring fault frequency of 119.922Hz and its harmonics are clearly visible.
No. 10 Wind Turbine/Gearbox High-Speed Shaft 5H/128k Acceleration Waveform (0.1-20000)_Spectrum Analysis
Envelope demodulation is mainly based on the bearing outer ring fault frequency.
No. 10 Wind Turbine/Gearbox High-Speed Shaft 5H/128k Acceleration Waveform (0.1-20000)_Envelope Demodulation
Comparing the time-domain waveforms in the early stage of the fault and the deterioration stage, it can be seen that the impact amplitude gradually increases, and the baseband energy also gradually increases.
Wind Turbine No. 10 / Gearbox High-Speed Shaft 5H/128k Acceleration Waveform (0.1-20000)_Time Domain Waveform
In the early stage of the fault, the spectrum energy is mainly concentrated in the low-frequency band, and the spectrum line is relatively clear; in the middle stage of the fault, obvious bearing outer ring raceway damage characteristics appear in a wider frequency band, and in the late stage of the fault, the spectrum line of the bearing outer ring fault frequency becomes blurred, and the noise energy increases significantly.
No. 10 Wind Turbine/Gearbox High-Speed Shaft 5H/128k Acceleration Waveform (0.1-20000)_Spectrum Analysis
3. Diagnosis Conclusion and Recommendations
3.1 Diagnostic Conclusion
2022-04-19 Push diagnosis conclusion: Early and mid-term damage to the outer ring of the high-speed shaft bearing of the gearbox, there is a small area of spalling, and it is currently slowly deteriorating.
3.2 Recommendations
The equipment is currently in a monitorable operating state, and it is recommended to arrange an inspection when appropriate. 1. Pay attention to recent changes in oil temperature and oil pressure in the SCADA system; 2. During routine inspections, pay attention to abnormal noises and temperature rise in the gearbox operation, and regularly improve lubrication to slow down the rate of deterioration.
4. On-site Maintenance Process
1. 2022-04-19 09:09 First reminder to the site to pay attention to the high-speed shaft bearing raceway damage, as mentioned above, it is recommended to keep an eye on it recently.
2. 2022-10-30 21:51 High-speed shaft bearing outer ring raceway deterioration, another reminder to pay attention, informing the site that long-term operation is not recommended.
3. 2022-11-11 10:14 The site feedback after endoscopic inspection showed severe spalling on the outer ring raceway of the bearing.
5. On-site Maintenance Photos
Endoscopic results show severe spalling on the outer ring raceway of the bearing.
Inspection Photo_1
Inspection Photo_2
6. Post-Maintenance Verification
The equipment has not been started since the overhaul.
7.Customer Feedback Form
Feedback Form_1
8.Monitoring Fault Range
The timely and effective collection of equipment operating status data (vibration, temperature) is subject to network smoothness and data transmission time, and also needs to consider the interference of equipment attributes, production technology and other factors. At the same time, the analysis and diagnosis of equipment status is based on the change of vibration effect caused by the failure of rotating moving parts. Therefore, the condition monitoring system cannot guarantee to monitor all types of faults. The monitoring system is configured according to the measuring point scheme recommended by Party B, and the monitoring fault range and description are as follows:
9.Precautions
1. If the client of this report cannot provide basic unit parameters (such as: unit transmission chain diagram, gearbox structure diagram, gearbox gear number, etc., related bearing models and brands), it will affect the accuracy of the analysis and diagnosis;
2. This report contains analyses, diagnoses, and maintenance suggestions for the unit from Rongzhi's professional technicians and is for reference only. The client should make its own decisions regarding specific maintenance and repair measures.
3. This report shall not be used as evidence for any claims, lawsuits, or other legal proceedings.
4. The client is obligated to keep the analysis report confidential and shall not provide this report to any third party, print it into other promotional materials, or publish it on public information platforms such as the Internet without the written permission of the trustee.

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Huate Dian Hebei Weizhou Wind Power Project 27#

1. Equipment Information
Equipment Type: Doubly-fed
Rated speed: 1812rpm
Measuring point associated with this case: High-speed shaft measuring point 6H
2. Alarm and Analysis Process
High-speed shaft gear failure identified during the physical examination.
2.1 Analysis Process
2.1.1 Description of evidence such as trends and index parameters
The total acceleration value of the high-speed shaft measuring point is relatively stable.
27#/High-speed shaft horizontal 5H/256k Acceleration waveform (2-2000)_Trend analysis
2.1.2 Description of evidence such as time domain, spectrum, and envelope demodulation
No significant impact is observed in the time domain waveform.
27#/High-speed shaft horizontal 5H/256k Acceleration waveform (2-2000)_Time domain waveform
Rich high-speed shaft rotation frequency sidebands are visible in the third-stage meshing in the spectrum.
27#/High-speed shaft horizontal 5H/256k Acceleration waveform (2-2000)_Spectrum analysis
3. Diagnosis and Recommendations
3.1 Diagnostic Conclusion
2023-04-20 11:25 Pushed diagnostic conclusion: There are broken teeth in the high-speed shaft gear, and the deterioration is obvious.
3.2 Inspection and Maintenance Recommendations
You can check the damage of the high-speed shaft tooth surface in the near future, prepare spare parts, and choose the opportunity to replace it.
4. On-site Inspection and Maintenance Process
2023-04-27 14:15 On-site feedback: It is indeed a broken tooth, just found, ready for maintenance.
5. On-site Inspection and Maintenance Photos
The photo shows a clear tooth fracture on the high-speed shaft of the gearbox.
Maintenance Photo_1
Maintenance Photo_2
6. Verification after Maintenance
After on-site maintenance, the high-speed shaft rotational frequency impact disappeared from the waveform, indicating that the maintenance improved the fault characteristics.
27#/High-Speed Shaft Horizontal 5H/256k Acceleration Waveform (2-2000)_Time Domain Waveform Spectrum Combination Diagram
7.Customer Feedback Form
Feedback Form_1
8.Monitoring Fault Range
The timely and effective collection of equipment operating status data (vibration, temperature) is restricted by network smoothness and data transmission time, and the interference of equipment attributes and production processes must also be considered. At the same time, the analysis and diagnosis of equipment status are based on changes in the vibration effects caused by rotating moving parts failures. Therefore, the condition monitoring system cannot guarantee monitoring of all types of failures. This monitoring system is configured according to the measurement point scheme recommended by Party B, and the monitorable fault range and description are as follows:
9.Precautions
1. If the client of this report cannot provide basic unit parameters (such as unit transmission chain diagram, gearbox structure diagram, gearbox gear number, related bearing models and brands), it will affect the accuracy of the analysis and diagnosis.
2. This report is the analysis, diagnosis, and maintenance opinions of the unit by Rongzhi professional technicians, and is for reference only. The specific maintenance measures need to be determined by the client.
3. This report is not to be used as evidence for any claims, lawsuits, etc.
4. The client is obliged to keep the analysis report confidential and shall not provide this report to a third party, print it into other promotional materials, or publish it on the Internet or other public information platforms without the written permission of the trustee.

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Huate Dian Shangyi Wang Yueliang Wind Farm 30# Wind Turbine

1. Equipment Information
Equipment Type: Doubly-fed
Rated Speed: Frequency Conversion Equipment
Measuring point associated with this case: Main Bearing 1H
2. Alarm and Analysis Process
Equipment Alarm Events:
2.1 Analysis Process
2.1.1 Evidence Description of Trends, Indicator Parameters, etc.
There are occasional high points in the recent acceleration amplitude of the main shaft measuring point.
30# Wind Turbine/Main Bearing 1H/256k Acceleration Waveform (0.1-2000)_Trend Analysis
2.1.2 Evidence Description of Time Domain, Spectrum, Envelope Demodulation, etc.
There are shocks in the filtered waveform with intervals close to the fault characteristic frequency of the main shaft bearing.
30# Wind Turbine/Main Bearing 1H/256k Acceleration Waveform (0.1-2000)_Time Domain Waveform
The low-frequency part has high background noise energy, and there are fault characteristic frequencies and harmonics of the main shaft bearing.
30# Wind Turbine / Main Bearing 1H / 256k Acceleration Waveform (0.1-2000)_Spectrum Analysis
The waveform contains impacts with suspected bearing cage fault characteristic frequency intervals, with poor regularity.
30# Wind Turbine/Main Bearing 1H/256k Acceleration Waveform (0.1-2000)_Time Domain Waveform
3. Diagnosis Conclusions and Recommendations
3.1 Diagnosis Conclusions
2023-07-25 11:02 Pushed diagnosis conclusion: Early to mid-stage damage to the main shaft bearing, mainly rolling surface pitting and spalling, rolling element pitting and spalling, and bearing cage force jamming, with slow deterioration in the near term.
3.2 Inspection and Maintenance Recommendations
The equipment is currently in a monitorable operating state. It is recommended to arrange an inspection at an opportune time. Pay attention to whether the main shaft bearing has abnormal noise and temperature rise, and check the lubricating grease for impurities during scheduled inspections.
4. On-site Inspection and Maintenance Process
2023-08-25 10:47 On-site feedback: 30# unit recently underwent maintenance, and the damage to the main shaft bearing was inspected.
5. On-site Inspection and Maintenance Photos
As can be seen in the photos, the inner and outer races of the main shaft bearing have obvious chipping, pitting, peeling, and flaking phenomena. The rolling elements have pits and surface spalling. The bearing cage is fractured, and the grease is blackened.
Inspection Photo_1
Inspection Photo_2
6. Verification After Maintenance
After on-site maintenance, the unit is currently not started.
30# Wind Turbine / Main Bearing 1H / 256k Acceleration Waveform (0.1-2000)_Time Domain Waveform Spectrum Combination Diagram
7.Customer Feedback Form
Feedback Form_1
8.Monitoring Fault Range
The timely and effective collection of equipment operating status data (vibration, temperature) is restricted by network smoothness and data transmission time, and the interference of equipment attributes and production processes must also be considered. At the same time, the analysis and diagnosis of equipment status are based on changes in the vibration effect caused by rotating moving parts failures. Therefore, the condition monitoring system cannot guarantee monitoring of all types of failures. This monitoring system is configured according to the measurement point scheme recommended by Party B, and the monitorable fault range and description are as follows:
9.Precautions
1. If the client commissioning this report cannot provide basic unit parameters (such as unit transmission chain diagram, gearbox structure diagram, gearbox gear numbers, relevant bearing models and brands), the accuracy of the analysis and diagnosis will be affected.
2. This report contains analysis, diagnosis, and maintenance suggestions from Rongzhi's professional technicians for the unit and is for reference only. The client commissioning this report shall decide on specific maintenance measures.
3. This report shall not be used as evidence for any claims, lawsuits, etc.
4. The client commissioning this report is obligated to keep the analysis report confidential and shall not provide this report to any third party, print it into other promotional materials, or publish it on the Internet or other public information platforms without the written permission of the trustee.

Learn More

Condition Monitoring for 100+ Wind Farms, Precision Alerts Ensure Stable Operation of Aging Assets

Client Requirements & Solutions

Application Value

Success Cases

1. Equipment Information

2. Alarm and Analysis Process

2.1 Analysis Process

3. Diagnosis Conclusion and Recommendations

3.1 Diagnostic Conclusion

3.2 Recommendations

4. On-site Maintenance Process

5. On-site Maintenance Photos

6. Post-Maintenance Verification

7.Customer Feedback Form

8.Monitoring Fault Range

9.Precautions

1. Equipment Information

2. Alarm and Analysis Process

2.1 Analysis Process

3. Diagnosis Conclusion and Recommendations

3.1 Diagnostic Conclusion

3.2 Recommendations

4. On-site Maintenance Process

5. On-site Maintenance Photos

6. Post-Maintenance Verification

7.Customer Feedback Form

8.Monitoring Fault Range

9.Precautions

1. Equipment Information

2. Alarm and Analysis Process

2.1 Analysis Process

3. Diagnosis and Recommendations

3.1 Diagnostic Conclusion

3.2 Inspection and Maintenance Recommendations

4. On-site Inspection and Maintenance Process

5. On-site Inspection and Maintenance Photos

6. Verification after Maintenance

7.Customer Feedback Form

8.Monitoring Fault Range

9.Precautions

1. Equipment Information

2. Alarm and Analysis Process

2.1 Analysis Process

3. Diagnosis Conclusions and Recommendations

3.1 Diagnosis Conclusions

3.2 Inspection and Maintenance Recommendations

4. On-site Inspection and Maintenance Process

5. On-site Inspection and Maintenance Photos

6. Verification After Maintenance

7.Customer Feedback Form

8.Monitoring Fault Range

9.Precautions

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