Temperature Sensor Failure in Wind Turbines: Challenges and Mitigation Strategies

Manoah Kingston, Deborah Joseph

Abstract: Wind turbines operate under complex environmental and mechanical conditions, making them susceptible to various component failures. One such critical issue is the failure of temperature sensors in the gearbox lubrication system, which plays a vital role in maintaining optimal operating conditions. Sensor failures can result in inaccurate temperature readings, leading to inadequate lubrication, overheating, component degradation, and unplanned turbine shutdowns. These failures not only impact turbine performance but also increase maintenance costs and downtime. Common failure modes include sensor failure, electrical interference, moisture ingress, and mechanical damage due to constant vibration. Identifying the root causes behind these failures is essential for improving reliability and operational efficiency. This paper explores these failure mechanisms and presents comprehensive mitigation strategies using the DMAIC (Define, Measure, Analyze, Improve, and Control) approach. By systematically defining failure modes, measuring their impact, analyzing root causes, implementing improvements, and establishing control measures, operators can ensure enhanced sensor performance and continuous and efficient turbine operation. Adopting these strategies can significantly reduce the risk of unexpected downtimes, optimize maintenance practices, and extend the lifespan of critical turbine components.

Keywords: Wind turbine, temperature sensor, failure analysis, gearbox lubrication, predictive maintenance, vibration-induced failures, sensor calibration, DMAIC methodology, torque optimization, real-time monitoring