Oil Management VGB Köln 150220
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Transcript of Oil Management VGB Köln 150220
Gearbox Oil Standard VGB Powertech Operation and maintenance conference Colone 24th february 2015 Thomas Stalin 2015-02-20
Confidentiality - Medium (C2)
Background
• Vattenfall has a long tradition handling oil, started its own oil laboratory in 1957 • Vattenfall has oil standards, Hydro and Nuclear and Distribution
• Vattenfall operates >1000 Turbines in DK, DE, NL, SE and UK • Turbines are from ?? Suppliers and ?? Models • Numerous Ways of handling oils today • Gearbox is the part that has the highest part of O&M Life Cycle Cost
- Designed for 20 years life time but fails in practice in many times after 2 to 5 years and hardly none survive 10 years
- Run gearbox with clean oil? - Prolong life time 50% or 3 times if compared to worst case
• Common approach on handling gearbox oil needed • Increase the knowledge level about oil and oil cleanliness • Optimize Oil Test Program • Cost saving
Confidentiality - Medium (C2)
Generation Wind Gearbox Oil Standard
• Instead of having a country and turbine specific way of handling gearbox oil we need a common approach - Procedure for Sampling of Oil, site specific - When to make sample - What Analysis to be performed and specifications on how - Which Laboratory to use and common purchase - Internal database for results - Enable Automated Evaluation of results together with CMS vibration
analysis and SAP data, type “Crystall Ball”
Related Oil Management Questions
• Introduction of offline filter analysis • Early detection of problem with debris sensor • Verification of filtration system • When to change filters • When to change gearbox oil and how to change it • Test of new Oil types
Confidentiality - Medium (C2)
Confidentiality - Medium (C2)
Additiv kemi
Base oil Additive package
1-10%
Corrosion inhibitor
Anti foam agent
Demulsifier agent
AW + EP
(Detergent, Engine oil)
(Dispergent, Engine oil)
VI-improver Pour Point Depressants
VI-improver
Antioxidant
Gearbox Oil
Base oil - Mineral - Polyalfaolefine - Polyglycol - Other
Confidentiality - Medium (C2)
Oil Cleanliness
• Gearbox oil needs to be clean and reach the level specified when gearboxes were designed.
• Report “Oil Cleanliness in Wind Power Gearboxes, Elforsk report 12:52, Jan Ukonsaari and Hans Möller”
• Oil film thickness 0,5 to 1,5 um, hair 17-180um • 80% of machine wear particle induced • Standard for counting level of particles ISO 4496:99
- 4, 6 and 14 um • Online and offline filtration
- 16/14/11 to 13/12/9 Vf offshore wind farm • Design level
- -/15/12 Vestas/Hansen - -/14/11 Winergy - 18/16/13 Literature - Faults during commisioning can not be reversed
• Clean oil can not recover design faults on drive train
Confidentiality - Medium (C2)
Bearing life and particles
P Particles in the EHL contact increase peak pressure
Elastic deformations
Increase sub surface fatigue, remaining
Dents reduce oil film
Create premature failure, spalling
Load dependent
Run in condition important
Confidentiality - Medium (C2)
Relative Bearing life, Particles
Confidentiality - Medium (C2)
Relativ Bearing life, Water content
TRAP Filter, Donaldsson
• Bearing manufacturers say that water in oil can severly damage bearings. - If gearbox survives 8 to 10 years maybee low water content can give
another 6 to 12 months life - Why descissant filters on hydraulic system that cost 10 times less than
a gearbox ???
• Only Gamesa has descissant filters on gearbox ventilation - Silica gel filter with limited capacity, work for 3 months not one year
• Instead Membran filter from Donaldsson
- From 400 PPM to 70 PPM Water - Lasting >1 year
Confidentiality - Medium (C2)
Confidentiality - Medium (C2)
Oil Quality Test
• How to create an optimized oil test procedure? - Create Value???
• At what time interval to make the test program? • Which type of test to be used and at what time?
- Older smaller turbine - Large existing turbines - New planned large projects
• How to introduce one site specific procedure to take oil sample - strictly to be followed - Otherwise results not comparable . To high variability.
• How to specify the oil analyses - Otherwise results not comparable and variability high. - Quality control of results
• Which Lab to use? - Common purchase
• Own Evaluation of Results from oil analysis and investigations from CMS system
Confidentiality - Medium (C2)
Optimized Oil Test Procedure
• During Warranty - Follow Turbine Manufacturers Recommendations but adopt these so
that sampling and testing show reliable results - Closely follow results during run in and warranty period!!!!
• After Warranty - Decide to establish own procedures based on own experience and
turbine manufacturers recommendations - Follow sampling procedure strictly - Education of the importance of oil cleanliness and on sampling method - Simplify procedures and have a common approach - Optimize Oil Testing
• Database for results • Own evaluation of results
- Together with CMS vibration analysis, SAP data and Chrystal Ball methodology
Confidentiality - Medium (C2)
Oil Sampling Horns Rev
Confidentiality - Medium (C2)
Oil Sampling Horns Rev cont
Lillgrund, GBX sampling
Confidentiality - Medium (C2)
Lillgrund Sampling Eguipment
Confidentiality - Medium (C2)
Lillgrund Hydraulic Oil
Confidentiality - Medium (C2)
Confidentiality - Medium (C2)
Education, oil quality and sampling procedures
• Presentation of Oil management standard for: - Site managers - Service leaders - Technicians
• Document present way of doing the job - Discussing findings with involved persons
• Propose possible improvements • Write site specific sampling procedure
- At the site together with the technicians - =>> Large improvements, 1 to 2 ISO classes cleaner oil
Confidentiality - Medium (C2)
Oil Analyses
• Goals for analysis - Check oil properties - Check appropriate levels of additives - Investigate machine wear
• Oil properties - Viscosity - Water content - Acid number - Foamability - Emulgation
• Levels of Additives
- Anti Wear and Extrem Pressure - Anti Oxidant - Anti Corrosion Inhibitors
• Machine Wear
- Particle counting - Levels of different element particles(atoms)
Confidentiality - Medium (C2)
Improve Evaluation of Results
• Need to make own evaluation of results from oil analysis - Oil good enough to run another year/6 months? - Prediction of gearbox breakdown?
• Or patient OK • Or ??? • Or dying?
• Evaluation of - Turbines in wind park - Fleet of turbines same model
• Service leader together with: - My support + Oil expert - If CMS with CMS expert
Actions??? =>Create Value!!!
BukobaThomas
Confidentiality - Medium (C2)
Östra Herrestad V90 2 MW, 9 turbines
• 10 times higher particle content than recomended • During EOW large particles found in offline filter, microscope inv.
- Cause not found and no Warrenty Issue • Inline filter half cold, => half fílled with air >> Reduced filter function
Two years of no action, further wear and deterioation
• Rebuild process at year four - Air release valve on inline filter - Air release valve on offline filter - Preassurising of offline filter, CCJensens/Stema
After 3 months 10 fold reduction of particles now all turbines better or equal to 16/14/11.
Cost around 500 Euro/turbine
Confidentiality - Medium (C2)
Östra Herrestad continue I
• Endoscopy investigation show all bearing surfaces with dents - Severly damaged, accelerated wear
• CMS system shows no indication of damages • Oil analyses show perfect oil cleanliness now
- Before high particle content and especially large particle >30>50>70 um. Look into the oil analyse sheet and analyse this information!!!!
- Large particles that should not be there and for which the gearbox bearings was not designed for. With inline filter 10 um and beta 200.
- Offline filter analyses show large particles 100x100x100 um - Microscopy investigation of particles in oil show 500 um hairline
extruded particles • Outer bearing ring rotates and releases particles that destroy bearing
surfaces • Outer ring fixation shaves off very long particles that breaks into smaller
particles that are transported through the bearing Confidentiality - Medium (C2)
Östra Herrestad continue II
• Original offline filter design HDU15/25 to small, designed for V52, 850 kW
• Particles accumulate at inline filter - At start and stop large amount of large particles recirculated - >>create severe damage - Finnish research paper:
• Second rebuild: - Double flow 120 to 250 liter/h - 8 fold increase of filter area, HDU 27/54 - Magnetic filter in the main circuit - >> Catch all large particles and stop recirculation of particles
By removing larger particles the speed of deteroation will slow down - Increase life by 6 to 12 months or more - Change to medicine oil with better additives: Duolec LE or Rewitech
Confidentiality - Medium (C2)
Confidentiality - Medium (C2)
Oil Exchange
• Oil should be changed based on Oil Quality Properties - Instead of exchanging an oil based on yearly intervals - Dialog with turbine manufacturers, gearbox suppliers and oil
companies should be started. Right conditions not known!!! • After five years the oil sample should be sent in for full analyze
- If Quality is acceptable good, the oil should be used for another 1year/6 months.
- When Oil reaches end of life it should be tested every 6 months. • Oil refilling procedures
- Oil should be filled via a filter with minimum oil cleanliness -/14/11 and acceptable level of oil cleanliness should be reached before turbine is taken in full operation.
- Oil should not be filled through open cans into gearbox • Batch of new oil analysed before filling
Confidentiality - Medium (C2)
Exchange to New type of oil
• During 20 years oil technology will improve with new formulas - Lower wear due to AW and EP aditives - Lower friction >>> higher production 0,5 to 1% - Vattenfall should try to improve the production by using new oils
• The specified oil for the gearbox has been chosen after a long test 3-5 years to approve new gearbox oil
• VF have had experience of large problems after changing from one type of gearbox oil to another type. - Long test had been made but small change in oil formula made new oil
forming glue like components when mixed with old oil - Great Care Needed!!!
• Change to new type of oil shall only be done after consultation with Vattenfall experts and careful testing. Permission should be needed.
• Common program to test and evaluate new type of oil formulas • 1) Polyalfaglycol Dow Ch., 2) Eco Gear Addinol, 3)Duolec LE,
4)Rewitech
VGB Powertech proposed Research Topics
Research projects: • Testing of present and new gearbox oil formulas • When to change gearbox oil • How to interpret results from wear debrice sensors, ei Gastops sensors • How to extend the fying out period by use of oils with special additives
and increased filtration and different control strategy
Best practises: • Gearbox oil management • Interpretation of gearbox oil analyses
Standards: • Format for reporting of oil analyses results • Oil analyses for Wind Turbine Gearbox oils
Confidentiality - Medium (C2)
Please contact me to discuss oilmanagement!!!
Confidentiality - Medium (C2)