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FUCHS PETROLUB AG1
Understanding what makes Wind Different Wind Power Applications Application Requirements Windpower Oil Windpower Greases Summary
AGENDA:
FUCHS LUBRICANTS
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Fuchs Lubricants is a $2 Billion Lubricants global manufacturer.
Fuchs has been in the Wind Business for almost 20 years.
Fuchs provides greases, oils and assosciated products to the Wind power industry.
Fuchs works closely with the OEM turbine manufacturers and the equipment manufacturers to provide premium products to the different and difficult Wind applications
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U.S. Wind Power, by State & Region
As of Sept 30th there were approximately 49,000 operating wind turbines in the U.S.
Source: AWEA 2015 3rd Qtr Report
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WIND POWER OPERATING CONDITIONS
300 Feet in the Air 6 Month Maintenance Cycle Intermittent and Variable Usage High Vibration Environment Extremely Large /Complicated / Expensive
Components Exposed to the Elements
What Makes Wind Different
WIND TURBINE – Working Principle
RotorBlades
Generator
Low speed shaft
Kinetic Energy
Mechanical Energy
Electrical Energy
High speed shaft
Wind Turbine Main Components and Lubrication Points
Yaw (Azimuth) bearing
Rotor bearing (Main bearing)
Generator bearing
Yaw drive
Pitch drive & Pitch bearing
Main gear
Generator bearings
Main bearings
Gear Box
Pitch/Yaw bearing
Yaw/Pitch Gear Teeth Flanks
Many Components
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$50,000 Lubricant only costs for wind turbine maintenance. How much grease and oil is used?
Huge potential lubricant related failure costs..What does a main bearing cost you?
Over $300,000 to replace a Main Gearbox, including Crane Charges
Too much , too little , too early , too late all can cost the Wind Farm money. How do you decide when and how much?
COSTS OF LUBRICATION
Different Components >> Different Requirements
Each component has different types of contact
Each component has different requirements
Each component requires a specific lubricant
HOW DO YOU DECIDE WHICH LUBRICANT TO USE
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Different Components >> Different Requirements
Main Gearbox OilLong Life ( desire 20 years, Ave = 5-7
years)High Costs of FailureLow Temp, High Speed, Moderate
LoadsComplex Gear and Bearing systemOil Changes are Expensive
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GE 2.9 two-stage planetary and one-stage parallel shaft (bottom) wind turbine gearboxes (Image: GE).
MAIN GEARBOX
MAIN GEARBOX OIL REQUIREMENTS
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Requirements and indicators for using
OIL in Wind Turbines
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GEAR OIL DATA
December 2012 - PM415
FAG 4 Step Test Results : general overview
WIND OIL TESTING -- FAG
SKF Test Results Part 3 :
Excellent:
•Corrosion Protection NaCl – Emcor test
•Oxidation stability•FE8 wear protection•Low foaming•......
WIND OIL TESTING -- SKF
Flender Foam Test Results
Oil Volume, 1Litre Spur Gears Oil Temperature, 25°C 5 Minutes Run Volume of Foam and Oil-Air Dispersion < 15% Foam, 1Minute after Stopping
WIND OIL TESTING --- FLENDER
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OIL FILTERABILTY
Test Fuchs Standard
MethodOther possible
Methods UnitFreshoil up to 4.000 h
or 6 month
24.000 hor 3 yrs Warning Limits
Appearance Visual Visual clear liquid precipitations
Color DIN ISO 2049 0 - 1,5 0 - 8 not applicable
Viscosity @ 40°C DIN EN ISO 3104 ASTM D 445 mm²/s 288 - 352 (typ.: 320) 270 - 405 < 270 or > 405
Viscosity @ 100°C DIN EN ISO 3104 DIN EN ISO 3104 mm²/s 29-39 ( typ.35 ) < 24 or > 45
Viscosity Index DIN ISO 2909 ... 135-161 < 130
Unresolved Material DIN EN 12662 DIN ISO 5884 % < 0.05 < 0,5 > 1
Ferrography IndexFLV-F-15 (Fuchs Lab-
method) PQ-Index Analizer ... < 20 < 100 > 100
Water content (Karl Fisher)
KF, indirectDIN 51777-2 DIN ISO 3733 mg/kg / ppm < 100 < 500 > 500
Density @ 15 °C DIN 51757 ASTM D 1298 kg / dm³ 0,850 - 0,8650,850 -
0,865 +/- > 15 %
Neutralization no. - TAN DIN 51558-1 ASTM D 664 or 974 mgKOH/g 0,4-0,7 (typ.: 0,6) < 2,0 > 2,0
TYPICAL OIL LIMITS
TYPICAL ELEMENT LEVEL FOR GEAR OIL
December 2012 - PM420
Used oil limits
Test / Prüfung Standards/ Methode Unit/Einheitfreshoil up to 4.000 h
or 6 month 24.000 h or ³3 yrs Warning Limits
Al content / Gehalt ICP (Plasma Spectrometer) mg/kg < 5 < 20 > 20
Fe content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 100 > 100
Zn * content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 50 > 50
Cu content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 50 > 50
Cr content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 20 > 20
Sn content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 20 > 20
Si content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 30 > 30
Mg * content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 50 > 50
Mo * content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 100 > 100
P content / Gehalt RFA (DIN 51363-2) mg/kg 190 - 250 > 150 < 150 or > 275
S content / Gehalt RFA (DIN EN ISO 14596) mg/kg 3800 - 4800 > 3000 < 3000 or > 5200
Ca content /Gehalt RFA (DIN 51363-2) mg/kg typ. 22 13- 50 < 5 or > 50
Cleanliness class / Reinheitsklasse ISO 4406 17 / 14 / 11***
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USED OIL ANALYSIS
GE 1.5 Turbine Winergy Gearbox
Attribute UnitComponent Gearbox Gearbox Gearbox Fresh oilOil
Measured Data :AO aminicaccording to Ruler
RAO[%] 75 97 63 -
phosphorus (RFA) mg/kg 359 343 337 236lead (ICP) mg/kg < 5 < 5 < 5 < 5iron (ICP) mg/kg 13 10 11 < 5zinc (ICP) mg/kg 190 180 170 < 5silicon (ICP) mg/kg < 5 < 5 < 5 < 5aluminium (ICP) mg/kg < 5 < 5 < 5 < 5copper (ICP) mg/kg < 5 < 5 < 5 < 5chromium (ICP) mg/kg < 5 < 5 < 5 < 5tin (ICP) mg/kg < 5 < 5 < 5 < 5magnesium (ICP) mg/kg 66 58 55 < 5nickel (ICP) mg/kg < 5 < 5 < 5 < 5molybdenum (ICP) mg/kg 64 49 50 < 5natrium (ICP) mg/kg 9 17 15 5calcium (ICP) mg/kg 13 13 12 19phosphorus (ICP) mg/kg 330 298 290 209barium (ICP) mg/kg < 5 < 5 < 5 < 5Viscosity@ 40C cst 332.5 327.8 326.5 320
TANmgKOH/g 0.72 0.75 0.77 0.4-0.7
Water Content PPM 24 76 72 < 100
Different Components >> Different Requirements
Yaw/Pitch Gearboxes and Hydraulic System Smaller , somewhat less critical applications Less lube usage
Yaw and Pitch Gear Teeth Flanks HIGH load Only a small % of the area used Vibration also an issue
Main Bearings Low Speed 23-30 RPM Fairly heavy loads Largest Grease user
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Diagram courtesy of NREL
Nacelle weights 56Blade assembly weights 36 Tons
KEY COMPONENTS
Different Components >> Different Requirements
Generator BearingsHigh Speed 12-18,000 RPM Lightly loadedHigh temp operation a concern
Yaw and Pitch Bearings High shock loading Limited movement, pitch has many more small adjustments
Low temp can be an issue
OthersFastener Lubrication/ProtectionChain Hoists / LiftsBalance of Plant24
FUCHS PETROLUB AG25
LUBRICATION INTERVAL
.. In other words…
HOW MUCH?
HOW OFTEN?
WHEN TO CHANGE?
….easy questions with an “uneasy answer”….
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LUBE INTERVAL AND VOLUME
What does the OEM say?
What does history tell you?
Are you using the proper lubricants?
Are you using auto lubricators?
Feed back from condition monitoring and oil/grease analysis?
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Do you have a predictive maintenance system?
Has the environment been different?
What do your technicians see?
SUMMARY
The Wind Market represents a unique and diversified lubrication challenge
Lubrication is an integral part of the entire Economic Structure of the Wind Turbine
As the components evolve and change so do lubricants
Each application has unique requirements that call for specific performance from the lubricant
The cost of the lubricant itself is only a small part of the total costs associated with the entire lubrication process
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THANKS FOR YOUR ATTENTION
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