Contamination Control For Wind Turbinesjacksr7/GradworkshopWind09/ASMEGradStud… · 10µ=Talcum...
Transcript of Contamination Control For Wind Turbinesjacksr7/GradworkshopWind09/ASMEGradStud… · 10µ=Talcum...
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Contamination ControlFor Wind Turbines
ASMEGraduate Student Workshop
October 2009
Bill NeedelmanChief Science AdvisorDonaldson Company, Inc
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Study by Professor E. Rabinowicz, MIT
Loss of Usefulness
Obsolescence
(15%)
Surface Degradation
(70%)
Accidents
(15%)
Corrosion
(20%)
Mechanical Wear
(50%)
Abrasion AdhesionFatigue
“Six to seven percent of the Gross National Product is required
just to repair the damage caused by mechanical wear.”
Note: Currently ~$1 trillion
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Wind TurbineReliability & Performance
• 25 % of Cost of Ownership of Wind Turbines is Maintenance
• Reliability Problems
Gearbox > Blades > Generators
• 80% Of Operating Problems Due to GBX
Mostly Gearbox Repair & Replacement
• Bearings are #1 Cause of Gearbox Failures
• Most Gearbox Warrantees ~2 Years,
Costly Repairs Start ~4th Year
• 90% Anticipated Energy Production
5% GBX, 3% Wind, 2% All Others
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Hard Particle DamageBearing Fatigue
0.001
0.01
0.1
1
40 50 60 70 80 90 100 110 120 130
Debris Particle Size
Life Relative to Non-Dented Bearings
Hard Ductile (e.g. T15 & 52100 Steel) Hard Rigid (e.g. Al2O3 & SiC) Hard Friable (e.g. TiC)
Ref: Kotzalas & Needelman, AWEA Wind Power Conf, 2008
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Outline
• Problems Caused by Oil Contamination
• Particle Filters
• Water Contamination Control
• Best Practices
• Benefits & Conclusions
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Types of Contaminants
Particles - Hard & Soft
Water
Air/Gases
Fuels, Acids, Glycols
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What is a MICRON ?What is a MICRON ?
40µµµµ
100 µµµµ
10
µµµµ
1µµµµ
PARTICLE SIZE
100µ=Grain of table salt
40µ=Lower limit of visibility
10µ=Talcum powder
2µ=Bacteria
Unit of Measurement
1 Millionth of a Meter (micrometer)
Or .000039"
µ = Micron Symbol
MICRON
70µ=Typical human hair diameter
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The Particle Zoo
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21/20/18
TOO DIRTY TO
EVALUATE
23/22/20
19/17/1518/16/14
26/24/22
20/19/17 16/15/13
15/14/1221/20/1821/20/18
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Major Types & Sources of Hard Particle Contaminants in Wind Turbines
• Hard Particles
– Manufacturing Swarf
• Machine Chips, Casting Sand, Grinding Debris, Abrasives
– Internal Wear Debris
• Gear Tooth Wear
– Internal Corrosion Products
• Rust, Aluminum Oxide
– Environmental Grit
• Airborne Mineral Dust, Sand
Bath Tub Model
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Hard Particle Problems
• Rolling Contact Fatigue
• Abrasive Wear & Erosion
• Lubricant Oxidation
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Abrasive Wear
Adhesive Wear
Rolling Contact Fatigue
Mechanical Wear By Hard Particles
All Three Forms of Wear
Result in Loss of Clearance,
Rough Surfaces, and
Greater Friction
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Gear Tooth ContactsSliding
Contacts
Rolling
Contact
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Gear Friction Increases As Gear Tooth Surface Roughens
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16
Rolling Contact Fatigue: Surface Origin Spalls
Initiation point
Roller Path
Spalled
Area
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Load
Dynamic Fluid Film
Thickness (µm)
Older Bearings Failed BySub-surface Initiated Fatigue Spalling
Slag Inclusion
In Steel
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Particles & Surface Initiated Fatigue
Particle CaughtParticle Caught
LoadLoad
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Particles & Surface Initiated Fatigue
LoadLoad
Surface Dented,
Crack Initiation
Surface Dented,
Crack Initiation
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Particles & Surface Initiated Fatigue
LoadLoad
Crack Propagation
Cracks Spread
With Repeated Cycles
Crack Propagation
Cracks Spread
With Repeated Cycles
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Particles & Surface Initiated Fatigue
Fatigue Spall Crater Forms
Hard Particles Released
Fatigue Spall Crater Forms
Hard Particles Released
LoadLoad
SpallSpallSpall
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The ChallengeCleaner Gear OilDrier Gear Oil
Same For Hydraulic Fluids
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����
Element Design����
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DT Steel Std
Collapse High Collapse
DT Steel
Coreless
1 Outer Wrap n/a n/a n/a
2 Support Mesh (2)
epoxy coated
steel for
support and
spacing
stainless steel
for support and
spacing
epoxy coated
steel for
support and
spacing
3 Flow Control Layers (2)
synthetic layers
to strengthen
media
synthetic layers
to strengthen
media
synthetic layers
to strengthen
media
4 Synteq® Media
thin glass-fiber
media for
performance
thin glass-fiber
media for
performance
thin glass-fiber
media for
performance
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Filter Media Types
- Cellulose
- Synthetic (Glass Fiber)
- Wire Mesh
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Pressure Loss Across A Filter Element(∆∆∆∆P)
Pressure Loss ∝∝∝∝ Flow Rate
X Viscosity
X Tortuosity
Gear Oil Oils: High Viscosity
Gear Boxes: Moderate Flow Rates
Fine Filters: High Tortuosity
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Pore StructureGraded Pore Filter Media
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State-Of-The Art Filter Media
Conventional Media
Resin Bonded
New Media
Bi-Component
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Thermoplastic B
Sheath
Bicomponent Binder Fiber
Thermoplastic A
Core
Glass
microfibers
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Bi-Component Filter Medium
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Bi-Component Filter MediumGlass
microfibers
Thermoplastic
binder
fiber
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Field Data: GE 1.5 MW
Turbine #5
0
1000
2000
3000
4000
5000
6000
7000
12/1/08 1/1/09 2/1/09 3/4/09 4/4/09 5/5/09 6/5/09 7/6/09 8/6/09
Dates
Particles/ml
>4um
>6um
>14um
Hydac 10um
DT 5um XPNew 5 um
Current 10 um
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Dissolved & Free Water
Free Water
Emulsified
Dissolved Water
Below
Saturation
Free Water
Bulk
Separation
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Major Sources of Water Contaminationin Wind Turbines
• Water Vapor - Humidity
• Rain (Through Vents & Seals)
• New Oil
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Oil Has A Relative Humidity (RH)
50% RH Oil
At Equilibrium
RH of Air
Equals
RH of Oil
(RH Oil = %Saturation)
Water
Molecules
50% RH Air
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Humidification
Water moves from high relative humidity
to low relative humidity
0
10
20
30
40
50
60
70
80
0 8 16 24
T im e (H ou rs )
Moisture Content (% Saturation)
Mobil DTE PM 220
in contact with air
controlled at 90oF
& 80% RH
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Problems Caused by Water Contaminationin Wind Turbines
• Rolling Contact Fatigue
• Adhesive Wear
• Additive Dumping
• Oil Oxidation
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Water DamageBearing Fatigue
0.1
1
10
10 100 1000
Water Concentration in Lubricant (PPM)
Relative Fatigue Life
SAE 20 + R&O SAE 5 + EP (100/X)^0.6 Navy Data
Ref: Kotzalas & Needelman, AWEA Wind Power Conf, 2008
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Water & Rolling Contact Fatigue
Oil + Dissolve Water Forced Into Cracks in the Contact Zone
LoadLoad
Water & Fatigue Crack Propagation
Hydrogen
Embrittlement
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Loss of Fluid Film Lubrication& Adhesive Wear
Load
Low Viscosity
Water Not Able
To Support Load
Film Collapses
Dynamic Fluid
Film Thickness (um)
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Water DamageAdditive Drop-Out
Fouled & Disabled Oil-Level Sensor
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Water DamageAdditive Drop-Out
Courtesy COT-Puritech, Inc.
Fouled & Disabled Thermostat
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Keeping Gear Oils & Hydraulic Fluids Dry in Wind Turbines
• Prevention
– Minimize Ingression
• Removal
– Rapid
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Regenerable Breather Dryer
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Inhalation ExhalationCaptures H2O Regenerates By
Releasing H2O
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Ultrapac
ARV-3: P568790
ARV-10: P568791
Customer Supplied
Pressure Regulator
with Guage
(set to 100 psi)
Incoming
Compressed Air
Customer Supplied
Shut-off Valve
(Required for
maintenance of unit)
Customer Supplied
Shut-off Valve
Reservoir
Customer Supplied
Flow Meter
(Optional to adjust
compressed air
usage as required)
TRAP Breather with
Tee and Relief Valve
Orifice
ARV-3: P568606
ARV-10: P568799
(Must be installed for proper
operation of ARV)
Inlet
Port
Outlet
Port
Inlet & Outlet Installed On
Opposite Corners Ideal
Dry Air Blanket System
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Dry Air Blanket System
Time
• Dry Air
• Dry Oil
• Humid Air
• Saturated Oil
• Purging
Humid Air
• Saturated Oil
• Dry Air
• Moisture
Desorbing
from Oil
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Na12 [(AlO2)12(SiO2)12] x H2O - 10 Angstrom Molecular Sieve
Pressure Swing Adsorption Dryer
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Dry Air Blanket Keeping Oil in Contact With Very Dry Air
0
10
20
30
40
50
60
70
80
0 8 16 24
Time (Hours)
Head Space Air Relative Humidity (%)
2
Reservoir Head Space Air
6
20
200
0
10
20
30
40
50
60
70
80
0.0 8.0 16.0 24.0
Time (Hours)
Oil Percent Saturation (%)
20
2
Reservoir Oil
200
6
Exchanges/hour
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Best PracticesTotal Contamination Control Plan
1) Design
2) Roll-Off Cleanliness
3) Transportation
4) On-Site Storage
5) Clean Maintenance Practices
6) Ingression Prevention
7) Rapid Removal
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Best Practices ForIngression Prevention & Rapid Removal
Inline Filter
ββββ5(c)=1000
Gearbox
Offline Filter
ββββ3(c)=1000
Offline Water
Absorption
Filter
Regenerable Breather
Dryer with 3 Micron Filter
Objectives: ISO 14/12/10
. 125 ppm max
Cooler
Dry Air
System
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NASA/STLE Roller Bearing
Life Factors for Wind Turbines
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0 5 10 15 20 25 30 35 40
Filter Rating Where ¬¬¬¬(C) = 1000
(Microns)
Bearing Life Factors
Adapted from Needelman & Zaretsky, STLE Annual Mtg. Proc. May 09
12 um10 um
8 um
5 um
2um
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NASA/STLE ModelWater Contamination & Bearing Life
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
0 100 200 300 400 500 600
Water (ppm)
Relative Bearing Life
Maintaining Dry Oil
Estimated To Increase
Bearing Life ~200%
Current
Target
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Conclusions
• Benefits Of Excellent Contam Control
– Greater Gearbox Reliability
–More Uptime, More Production
– Extended Warrantees
– Up To 5 Year Gear Oil Life
• Needed
– Coherent Contamination Control Plan
– Use Best Technologies & Practices
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Thank You For Your Interest
__________________
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