Can’t understand why certain performance problems keep recurring with your wind turbines? Let PSI Repair Services show you the importance of identifying the source of electronic-related performance problems with root cause analysis. As a leading Independent Service Provider (ISP) in the wind energy industry, PSI uses innovative methods to determine the root cause of failures and then engineers custom solutions to resolve these problems. In this informative webinar, PSI will provide real-world examples of how its powerful root cause analysis methods have helped resolve recurring failures of electronic parts and systems. In addition, you will see how diagnostic data can be used to develop improvements and replacements for underperforming components. Don’t miss out on this valuable event.

1. Root Cause Analysis: Understand Why
Electronic Parts Fail In Your Wind Turbine

2. q This webinar will be available afterwards at
www.windpowerengineering.com & email
q Q&A at the end of the presentation
q Hashtag for this webinar: #WindWebinar
Before We Start

3. Michelle Froese
Moderator
Windpower Engineering
& Development
John Greulich
Director of Sales
PSI Repair Services, Inc.
Aaron Lawson
Project Manager
PSI Repair Services, Inc.
Root Cause Analysis: Understand Why Electronic Parts Fail In Your Wind Turbine

4. #WindWebinar http://info.psi-repair.com/wind-root-cause-analysis

5. #WindWebinar
OUR LIVONIA CAMPUS

6. #WindWebinar
OUR CAPABILITIES
REPAIR
SERVICES
ENGINEERING
SERVICES
ONLINE
SERVICES
SURPLUS
SERVICES
• ELECTRONIC
• MECHANICAL
• BALL SCREW
• RAC® REPAIRABLE
ASSET CONTROL
• BUY SURPLUS PARTS
• SELL SURPLUS PARTS
• ELECTRONIC DESIGN
• MECHANICAL DESIGN
• MANUFACTURING
• FAILURE ANALYSIS

7. #WindWebinar
• Ford Motor
• Bosch
• General Motors
• Chrysler
• Delphi
• Hyundai
• Denso
• Thyssenkrupp
• Toyoda
• Honda
• EDPR
• EDF Renewable Energy
• NextEra Energy, Inc.
• Iberdrola
• Invenergy
• MidAmerican Energy
• NavAir
• Raytheon
• Naval Surface Warfare
• Naval Air Warfare
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• Wyle
• DRS
OUR CUSTOMERS
AUTOMOTIVE
INDUSTRY
WIND ENERGY
INDUSTRY
MILITARY
INDUSTRY

8. #WindWebinar
• Texas Instruments
• Western Digital
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• IBM
• Intel
• Freescale
• Samsung
• Maxim
• Seagate
• Triumph
• Chromalloy Gas Turbine
• Boeing
• Honeywell
• Kwikset
• Lufkin
• Corning
• SKF
• Black& Decker
• Briggs & Stratton
• Timken
• Honeywell
• Alcoa
• Eaton
OUR CUSTOMERS
SEMICONDUCTOR
INDUSTRY
AEROSPACE
INDUSTRY
MANUFACTURING
INDUSTRY

9. #WindWebinar
WHEN YOU THINK ISP, THINK PSI
• Hydraulic actuators
• Hydraulic pump
• Proportional valves
• Pitch motors
• Encoders
• Gear boxes – light duty
• Transducers
COMPONENT
REPAIRS
• Printed circuit board
• PLC
• Thyristors
• MET boards
• SCADA
• Pitch controls
• Monitors and displays
ELECTRONIC
REPAIRS
• Current controllers
• Anemometers
• IGBT banks
• Power converters
• Inverters
PSI is a leading independent service provider (ISP) to the wind industry. PSI offers
component repair and engineering services for these component failures and more:

10. #WindWebinar
The highest-level cause
of a problem is called the
Root Cause.
WHAT IS: A ROOT CAUSE
ROOT CAUSE
HIGHER-LEVEL CAUSE
FIRST-LEVEL CAUSE
VISIBLE PROBLEM
SYMPTOM

11. #WindWebinar
A Root Cause is “the evil at the bottom” that sets in
motion the entire cause-and-effect chain causing the problem(s).
Our goal is to permanently eliminate these through design improvements.
Root Cause Examples for Electronics:
• Faulty or weak components
• External causes, e.g. power issues
• Poorly designed circuits, underrated components
WHAT IS: A ROOT CAUSE

12. #WindWebinar
Root Cause Analysis (RCA) is a term
that describes techniques and tools used
to uncover causes of problems.
WHAT IS: A ROOT CAUSE ANALYSIS
CAUSE
CAUSE
CAUSE
CAUSE
PROBLEM
SYMPTOMS
The symptom is just the
Tip of the iceberg!

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Failure Root Cause
Edges of Tire Worn Under Inflation
Center of Tire Worn Over Inflation
Knife Stuck in Sidewall You Really Upset Someone!
EXAMPLE: FAILED TIRES

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5 WHYS is a technique used to explore the
cause-and-effect relationships underlying a
particular problem.
The primary goal is to determine the root cause
of a problem by repeating the question
"WHY?"
TOOLS OF RCA: 5 WHYS?

15. #WindWebinar
BELT
BEYOND
LIFE
BELT
BROKEN
ALTERNATOR
NOT
WORKING
BATTERY
DEAD
CAR
WON’T
START MAINTENANCE
NOT
PERFORMED
SCHEDULE
PREVENTATIVE
MAINTENANCE
TOOLS OF RCA: 5 WHYS?
WHY?
WHY?
WHY?
WHY?
WHY?
ROOT CAUSE
CORRECTIVE
ACTION

16. #WindWebinar
Pareto Analysis is a technique used for the selection of a
limited number of tasks that produce significant overall effect.
It uses the Pareto Principle (also known as the 80/20 rule).
Doing 20% of the work can generate 80% of the benefit of doing
the entire job.
TOOLS OF RCA: PARETO ANALYSIS OR RED-X
80%
RESULTS
20% EFFORT

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= 80% of the failures These are the most
critical problems to
address.
TOOLS OF RCA: PARETO ANALYSIS OR RED-X

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The Fishbone Diagram identifies many possible causes for an effect
or problem. It can be used to structure a brainstorming session. It
immediately sorts ideas into useful categories.
Also known as:
Ishikawa Diagram
Herringbone Diagram
Cause-and-Effect Diagram
TOOLS OF RCA: FISHBONE DIAGRAM

19. #WindWebinar
TOOLS OF RCA: FISHBONE DIAGRAM

20. #WindWebinar
• Extend MTBF
(Mean Time Between Failures)
• Save LABOR costs
• Prevent turbine DOWNTIME
• Less EXPENSIVE than OEM solutions
• Avoid major RETROFITS or overhauls
• Prevent CATASTROPHIC failures
before they happen
WHY RCA: IS SO CRITICAL TO O&M BUDGETS

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.
CASE STUDIES:

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0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
35.00%
40.00%
Percent of Total
Cumulative Percentage
80%
Majority of Failures
Related to IGBT
CASE STUDY: YAW MOTOR MODULE

23. #WindWebinar
Problem:
• 35 AMP modules failing
OEM Solution:
• Retrofit cabinets with 45 AMP module
PSI Solution:
• Upgrade 35 AMP module to 45 AMP
CASE STUDY: YAW MOTOR MODULE

24. #WindWebinar
Issues with OEM
Solution:
• New unit is wider
• Cabinets require modifications
• Retrofit labor is costly
• Larger units are costly
Result:
• Expensive solution
CASE STUDY: YAW MOTOR MODULE

25. #WindWebinar
Upgrades consisting of:
• 30 AMP IGBT replaced with 45 AMP device
• Recalibrate current sense resistors
• This provides additional current handling
for peak energy
CASE STUDY: YAW MOTOR MODULE

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0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0
1
2
3
4
5
6
7
8
9
10
# Parts Replaced
Cumulative %
80% Mark
CASE STUDY: PITCH BATTERY CHARGER

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Testing Data:
VA ratings exceeded of all
style transformers at nominal
input voltage.
CASE STUDY: PITCH BATTERY CHARGER

28. #WindWebinar
Original Design Problems:
• High failure rate
• Common component failures
• Transformer power exceeded
• Ambient temperature exceeded
CASE STUDY: PITCH BATTERY CHARGER

29. #WindWebinar
Transformer Failure Analysis:
Primary winding failed due to excess power and
ambient temperature.
CASE STUDY: PITCH BATTERY CHARGER

30. #WindWebinar
Upgrades Consist of:
• Higher power transformer and custom
adapter board
• Higher temperature IC’s
• Other high failure parts include
electrolytic capacitors replaced on each unit
CASE STUDY: PITCH BATTERY CHARGER

31. #WindWebinar
What happened? The Automatic Lubrication System failed.
WHY? The power supply failed.
WHY? The power supply has burned components.
WHY? The components got too hot.
WHY? The power supply produces a lot of heat.
WHY? The power supply is an inefficient design.
WHY? The power supply is old technology.
Solution?
Design an efficient power supply!
CASE STUDY: AUTOMATIC LUBRICATION SYSTEM
FIVE WHYS?

32. #WindWebinar
• Drop in replacement unit
• Custom designed
• Higher efficiency = low heat
• High reliability
• Low cost
CASE STUDY: AUTOMATIC LUBRICATION SYSTEM

33. #WindWebinar
FAILED UNITS
ENVIRONMENT
MATERIALS PEOPLE
Shipping Damage
ESD Damage
Low MTBF
Bad Design
Poor Ratings
Power Surges
Low Temp
High Temp
CASE STUDY: RFID TAG READER

34. #WindWebinar
Root Causes of Main Failures:
• Component temperature exceeded
• Poor antenna design
• Poor antenna matching circuit
CASE STUDY: RFID TAG READER

35. #WindWebinar
Poorly Designed OEM Antenna Antenna Redesign and Optimization
Copper Tape Style
Non-Optimized
Style
Multiple Designs
Simulated and Tested
In-House Prototypes
Production Design
with Coax Cable
SPICE Simulations
CASE STUDY: RFID TAG READER

36. #WindWebinar
• Custom designed and optimized antenna
• Range increased from 2.5cm to 5cm
• Higher temperature components
• Coax cable to antenna
• Brighter LEDs
• Over 1,000 field installations
CASE STUDY: RFID TAG READER

37. #WindWebinar
What did the customer like most about the new design?
• Increased range?
• Longer life?
• NO?
Brighter LEDs
can be seen more easily
Original LEDs
CASE STUDY: RFID TAG READER

38. #WindWebinar
WHY?
OLD TECHNOLOGY
TRANSISTORS
WHY?
POOR QUALITY
CAPS
WHY?
CAP ESR TOO HIGH
WHY?
TRANSISTORS
GENERATE TOO
MUCH HEAT
WHY?
CAPS LEAKED AND
SHORTED TRACES
WHY?
TEMPERATURE WAS
EXCEEDED
WHY?
IT HAS BURNED
CAPS
WHY?
THE PCB IS BURNED
WHAT HAPPENED?
PITCH DRIVE FAILED
WHY?
AMBIENT TEMP
GETS TOO HIGH
5 WHYS?
Multiple Paths and
Multiple Root Causes
CASE STUDY: PITCH MOTOR DRIVE

39. #WindWebinar
Problems with original design:
• Extremely short life: <2 years in most cases
• Catastrophic failures – Many units non-repairable
• Units up tower in hub – Expensive to replace
• Poorly rated capacitors and transistors
• Inefficient design generates excess heat
• Damaged threads on ground lug hole
CASE STUDY: PITCH MOTOR DRIVE

40. #WindWebinar
New Design Features:
• Higher efficiency: 25ºC cooler than OEM
• Allows repair of catastrophic failures
• FETs with lower on resistance
• Capacitors handle higher ripple current
• Thicker copper traces on PCB
• Over 3,000 field installations
• MTBF reduced by over 80%
CASE STUDY: PITCH MOTOR DRIVE
Steel Inserts create
more durable ground
lug threads.

41. #WindWebinar
CASE STUDY: CURRENT CONTROLLER
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
0
5
10
15
20
25
30
35
Pareto Analysis:
Large variation
in failures
VRCC Rotor Current
Controller

42. #WindWebinar
• Component rotates with generator
• High vibration environment
• Short MTBF
• High ambient temperatures
CASE STUDY: CURRENT CONTROLLER

43. #WindWebinar
Original Design Problems:
• Broken solder joints on capacitors
• High vibration during operation
• DC-DC converter failures
• Rotating component is poorly balanced
CASE STUDY: CURRENT CONTROLLER

44. #WindWebinar
Upgrades:
• Tab style mechanical connections on
snubber capacitors
• Through hole solder joints eliminated
• Resistant to damage from vibration
• Repaired units balanced with custom,
mechanically secured weights.
• Improved DC-DC converters
New PSI Snubber
Board Design
CASE STUDY: CURRENT CONTROLLER

45. #WindWebinar
WHEN YOU THINK ISP, THINK PSI
To learn more about Wind Energy Life Cycle Solutions,
visit http://info.psi-repair.com/wind-root-cause-analysis,
or call John Greulich at 734-853-5360.

46. Questions?
Root Cause Analysis: Understand Why Electronic Parts Fail In Your Wind Turbine
John Greulich
Director of Sales
PSI Repair Services, Inc.
john.greulich@psi-corp.com
Aaron Lawson
Project Manager
PSI Repair Services, Inc.
alawson.rsi@psi-corp.com
Michelle Froese
Moderator
Windpower Engineering
mfroese@wtwhmedia.com

47. Thank You
q This webinar will be available at
www.windpowerengineering.com & email
q Tweet with hashtag #WindWebinar
q Connect with Windpower Engineering & Development
q Discuss this on EngineeringExchange.com