AGENDA: Understanding what makes Wind Different Wind Power Applications Application Requirements Windpower Oil Windpower Greases Summary

Transcription

1 1 FUCHS PETROLUB AG

2 AGENDA: Understanding what makes Wind Different Wind Power Applications Application Requirements Windpower Oil Windpower Greases Summary

3 FUCHS LUBRICANTS 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 3

4 U.S. Wind Power, by State & Region As of Sept 30th there were approximately 49,000 operating wind turbines in the U.S. 4 Source: AWEA rd Qtr Report

5 WIND POWER OPERATING CONDITIONS What Makes Wind Different 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 5

6 WIND TURBINE Working Principle Kinetic Energy Mechanical Energy Electrical Energy Low speed shaft Rotor Blades Generator High speed shaft

7 Wind Turbine Main Components and Lubrication Points Yaw drive Main gear Generator bearing Yaw (Azimuth) bearing Rotor bearing (Main bearing) Pitch drive & Pitch bearing

8 Many Components Gear Box Pitch/Yaw bearing Generator bearings Main bearings Yaw/Pitch Gear Teeth Flanks

9 COSTS OF LUBRICATION $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? 9

10 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 10

11 Different Components >> Different Requirements Main Gearbox Oil Long Life ( desire 20 years, Ave = 5-7 years) High Costs of Failure Low Temp, High Speed, Moderate Loads Complex Gear and Bearing system Oil Changes are Expensive 11

12 MAIN GEARBOX GE 2.9 two-stage planetary and one-stage parallel shaft (bottom) wind turbine gearboxes (Image: GE). 12

13 MAIN GEARBOX OIL REQUIREMENTS Requirements and indicators for using OIL in Wind Turbines 13

14 14 GEAR OIL DATA

15 WIND OIL TESTING -- FAG FAG 4 Step Test Results : general overview 15 December PM4

16 WIND OIL TESTING -- SKF SKF Test Results Part 3 : Excellent: Corrosion Protection NaCl Emcor test Oxidation stability FE8 wear protection Low foaming...

17 WIND OIL TESTING --- FLENDER 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

18 18 OIL FILTERABILTY

19 TYPICAL OIL LIMITS Test Fuchs Standard Method Other possible Methods Unit Freshoil up to h or 6 month h or 3 yrs Warning Limits Appearance Visual Visual clear liquid precipitations Color DIN ISO ,5 0-8 not applicable 40 C DIN EN ISO 3104 ASTM D 445 mm²/s (typ.: 320) < 270 or > C DIN EN ISO 3104 DIN EN ISO 3104 mm²/s ( typ.35 ) < 24 or > 45 Viscosity Index DIN ISO < 130 Unresolved Material DIN EN DIN ISO 5884 % < 0.05 < 0,5 > 1 Ferrography Index FLV-F-15 (Fuchs Labmethod) PQ-Index Analizer... < 20 < 100 > 100 Water content (Karl Fisher) KF, indirect DIN DIN ISO 3733 mg/kg / ppm < 100 < 500 > C DIN ASTM D 1298 kg / dm³ 0,850-0,865 0,850-0,865 +/- > 15 % Neutralization no. - TAN DIN ASTM D 664 or 974 mgkoh/g 0,4-0,7 (typ.: 0,6) < 2,0 > 2,0

20 TYPICAL ELEMENT LEVEL FOR GEAR OIL Used oil limits Test / Prüfung Standards/ Methode Unit/Einheit freshoil up to h or 6 month 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 ) mg/kg > 150 < 150 or > 275 S content / Gehalt RFA (DIN EN ISO 14596) mg/kg > 3000 < 3000 or > 5200 Ca content /Gehalt RFA (DIN ) mg/kg typ < 5 or > 50 Cleanliness class / Reinheitsklasse ISO / 14 / 11*** 20 December PM4

21 USED OIL ANALYSIS GE 1.5 Turbine Winergy Gearbox Attribute Unit Component Gearbox Gearbox Gearbox Fresh oil Oil 21 Measured Data : AO aminic RAO according to Ruler [%] phosphorus (RFA) mg/kg lead (ICP) mg/kg < 5 < 5 < 5 < 5 iron (ICP) mg/kg < 5 zinc (ICP) mg/kg < 5 silicon (ICP) mg/kg < 5 < 5 < 5 < 5 aluminium (ICP) mg/kg < 5 < 5 < 5 < 5 copper (ICP) mg/kg < 5 < 5 < 5 < 5 chromium (ICP) mg/kg < 5 < 5 < 5 < 5 tin (ICP) mg/kg < 5 < 5 < 5 < 5 magnesium (ICP) mg/kg < 5 nickel (ICP) mg/kg < 5 < 5 < 5 < 5 molybdenum (ICP) mg/kg < 5 natrium (ICP) mg/kg calcium (ICP) mg/kg phosphorus (ICP) mg/kg barium (ICP) mg/kg < 5 < 5 < 5 < 5 Viscosity@ 40C cst TAN mgk OH/g Water Content PPM < 100

22 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 RPM Fairly heavy loads Largest Grease user 22

23 KEY COMPONENTS Nacelle weights 56 Blade assembly weights 36 Tons Diagram courtesy of NREL 23

24 Different Components >> Different Requirements Generator Bearings High Speed 12-18,000 RPM Lightly loaded High 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 Others Fastener Lubrication/Protection Chain Hoists / Lifts Balance of Plant 24

25 25 FUCHS PETROLUB AG

26 LUBRICATION INTERVAL.. In other words HOW MUCH? HOW OFTEN? WHEN TO CHANGE?.easy questions with an uneasy answer. 26

27 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? Do you have a predictive maintenance system? Has the environment been different? What do your technicians see? 27

28 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 28

29 29 THANKS FOR YOUR ATTENTION