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Why is clean oil so important in a wind turbine gearbox? Discover the benefits of controlling contamination in gear oil for enhancing reliability and extending life of gearboxes and their lifeblood, the lubricating oil. See how other owners and operators have slashed operations and maintenance costs.
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CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 1
2011 Wind Turbine Condition Monitoring Workshop
The Road Map to Effective Contamination Control in Wind Turbines:
Lessons From Condition MonitoringJustin StoverC.C. Jensen
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 2
Wind Turbine Manufacturer
Collaborating Partners (Design Offices)
Gearbox Manufacturers / Lubrication Systems
Our Experience… >70,000 Wind Turbines
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 3
0
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0 10 20 30 40
106 rotations
MacPherson Graph 1
Level of Filtration in Microns
The graph is based on a test with 10 bearings. The lubricant was contaminated by wear from gearboxes.
The Importance of Clean Oil
Life Extension!
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 4
The Importance of Clean OilConcluding Remarks from Bo O. Jacobson in his book
Rheology and Elastohydrodynamic Lubrication 2
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 5
Gearbox Flushing and Condition Monitoring
Filter System with Built In Particle Counter
Filter system validates that oil is clean during run-in and factory tests3
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring
2/3 load
TIME (Minutes)
Static Dynamic 1/3 load 100% load
TIME (Minutes)
Page 6
ISO
CO
DE
(O
il Cleanliness)
Target :
ISO Code ≤ 17 / 15 / 11
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 7
What Happens Before a Breakdown?
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 8
What Initiated the Breakdown?December 25th - 26th
Wear particles increase from 1,000 to more than 18,000 particles/ml (21 µm) at Start Up (Full Load & Low Temperature)
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 9
Wear Particles Found During Service Stop
Micropitting and Macropitting Observed On Gears
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 10
Many wear particles found on the filter’s surface
Magnification shows metal wear particles (70% of filter’s surface covered)
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 11
Offline Filter w/ Particle Counter Retrofit2.0 MW Turbine
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 12
What Happens If The Offline Filter Insert Is Removed?1.5 MW Turbine with Offline Filter and Particle Counter Installed 2006
Offline Filter Insert Removed 2009
Turbine Originally Equipped with a 10 Micron Inline Filter and 3 Micron Bypass Filter
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 13
Overview: Offline Filter Insert Removed
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 14
Offline Filter Insert Removed4 Micron Particles
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 15
Test Bench: 10 Micron Fiberglass Inline Filter
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 16
4 Micron Particle Peaks During Start/StopInline Filter Releases Particles
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 17
What Happens to the Particles Released by the Inline Filter?
Red Particles Released By Inline Filter Captured
by Offline Filter
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 18
What Happens to Inline Filter Performance when the Oil is Suddenly Cooled?
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 19
Nano-FiltrationIs It Important To Remove Submicron Particles?
Particle Size Distribution12, 10, 5, 3, 2, 1, 0.8, 0.6, 0.4, 0.2 Micron
Top Row: Red Iron Oxide Test DustBottom Row: Actual Particles From Used Gear Oil
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 20
Nano-Filtration of Used Gear Oil
1 = New Gear Oil2 = Nano Filtered (Final)3 = Nano Filtered (Intermediate)4 = Used Gear Oil
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 21
Removal of Submicron Particles2.0 MW Turbines Retrofitted with Offline Filter
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 22
Removal of Submicron Particles1.5 MW Turbines Retrofitted with Offline Filter
May (Retrofit)MPC 39
July (3 Months)29 MPC
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring Page 23
1. The importance of clean oil in gearboxes and bearings has been well documented for decades
2. Clean oil must be a focus throughout the lifecycle of a gearbox – from the cradle to the grave
3. Condition Monitoring validates that a filtration scheme that includes Inline and Offline Filters keeps the dirt content as low as possible and this ‘always pays’ off in less wear and tear, greater reliability and longer lifetime
4. Condition Monitoring proves that when an offline filter is removed the oil gets dirtier
5. Condition Monitoring confirms that Inline Filters release particles during cold starts and their inability to maintain cleanliness as the temperature decreases
6. Submicron particles must also be controlled with nano-filtration and monitored with analyses such as SEM-EDS and MPC .
CONCLUSIONS
CLEAN OILBRIGHT IDEAS
The Road Map to Effective Contamination Control in Wind Turbines: Lessons From Condition Monitoring
1. Sayles, R. and Macpherson, P. (1982). Influence of Wear Debris on Rolling Contact Fatigue. Rolling Contact Fatigue of Bearing Steels. ASTM STP 771. pp. 255-274.
2. Jacobson, Bo O. (1991). Rheology and Elastohydrodynamic Lubrication. Published by Elsevier Science Ltd p. 351
3. Errichello, R. and Muller, J. (2002). Oil Cleanliness in Wind Turbine Gearboxes. Machinery Lubrication, July/August, 2002, pp. 34-40.
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