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How to Reduce OpEx With Engineered Parts

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Windpower Engineering & Development
Windpower Engineering & Development

A new strategy for reducing OpEx on a wind farm is by using engineered parts that are designed to last longer, be replaced less frequently, and increase the life of the asset, ultimately reducing operating expenses. This webinar will go in depth on how to preserve oil condition in order to extend the life of the gearbox with the use of FilterMag®. Doug Viner, Mechanical Engineer at UpWind Solutions, and Randy Yount, Vice President of Operations at FilterMag®, will both be presenting on the value of engineered parts for wind farm owners.

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#WindWebinar Reducing OpEx With Engineered Parts: Gearbox Life Extension
#WindWebinar q  This webinar will be available afterwards at www.windpowerengineering.com & email q  Q&A at the end of the presentation q  Hashtag for this webinar: #WindWebinar Before We Start
#WindWebinar Michelle Froese Moderator Windpower Engineering & Development Randy Yount Vice President FilterMag Doug Viner Mechanical Engineer Upwind Solutions Reducing OpEx with Engineered Parts – Gearbox Life Extension Meet your presenters…
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions”
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” Gearboxes not lasting 20 year design life à Need for condition monitoring
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” Gearboxes not lasting 20 year design life à Need for condition monitoring Gearboxes, when they eventually fail, cause a lot of downtime.
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” Gearboxes not lasting 20 year design life à Need for condition monitoring 1.  Temperature 2.  Vibration 3.  Borescope inspection…
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions”
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions”
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions”
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions”
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!”
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3  +25% +100% same effect
#WindWebinar ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3  (1) This is easy for a WTG. Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” +25% +100% same effect
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3  (1) This is easy for a WTG. (2) But this takes a big toll. +25% +100% same effect
#WindWebinar Inner Race, “unwrapped” HSS-B Bearing Outer Race Rolling Elements
#WindWebinar ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/ ∆ 𝐿𝑜𝑎𝑑 )↑3  “And then what?”
#WindWebinar “Oh.” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/ ∆ 𝐿𝑜𝑎𝑑 )↑3 
#WindWebinar Cracked outer race HSS-C Bearing Pitted & deformed balls
#WindWebinar Image  Title Image  Title Case study available here: www.UpWindSolutions.com/blog/forensics-of-a-hss-bearing-failure
#WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” Gearboxes not lasting 20 year design life à Need for condition monitoring 1.  Temperature 2.  Vibration 3.  Borescope inspection 4.  Oil analysis (at last!) •  Can correlate oil particles with failure
#WindWebinar
#WindWebinar Humans  can   resolve OEM  filter  can   remove
#WindWebinar Mechanisms of Wear 1.  Abrasive Wear Particles between adjacent moving surfaces 2.  Adhesive Wear Metal to metal contact (insufficient lubricant film) 3.  Fatigue Wear Surfaces subjected to repeated stress 4.  Erosive Wear High velocity fluid (usually with particles) 5.  Corrosive Wear Chemically induced Water or chemical
#WindWebinar Lubricant Contamination Internal - generated by friction and wear ©Paul  Filter  Corp  1995 External - water, dirt, and sand through gearbox seals or breather
#WindWebinar Particle Sizes
#WindWebinar Measuring Contaminants Human hair (~75 µm) at 100x Magnification Particles (~10µm)
#WindWebinar Typical Clearances Clearance  in   Microns Component
#WindWebinar Lubricating Film Thickness Machine Clearance Operating or Dynamic Clearance Machine clearance and operating or dynamic clearance are not equal. Operating clearance depends upon the load, speed and lubricant viscosity. A lubricant film separates moving surfaces to prevent metal-to-metal contact. 5µm 5µm ≤10µm
#WindWebinar Elastohydrodynamic Lubrication ≤10µm•  Typical for rolling element bearings •  Elastic metal deformation •  Pressures reaching 350,000 psi •  Particles in oil flow into the film space •  Size depends upon operating conditions •  Trapped particles may indent the surfaces •  Cause pin point loading and stresses
#WindWebinar Elastohydrodynamic Lubrication ≤10µm
#WindWebinar Particle Counting / Reporting •  Measured by laser or white light scatter counter •  Counts the number of particles by estimated size •  4406:99 - Standard for particle count reporting
#WindWebinar Particle Counting / Reporting Par$cles   per  Milliliter   Range   More   Up  To  &   Code   Than   Including   >28   2,500,000       28   1,300,000   2,500,000   27   640,000   1,300,000   26   320,000   640,000   25   160,000   320,000   24   80,000   160,000   23   40,000   80,000   22   20,000   40,000   21   10,000   20,000   20   5,000   10,000   19   2,500   5,000   18   1,300   2,500   17   640   1,300   16   320   640   15   160   320   14   80   160   13   40   80   12   20   40   11   10   20   10   5   10   Notes: 1)  Each code range is approximately double the previous range 2)  One code change could be 1 particle or ~4X the number of particles
#WindWebinar Particle Counting / Reporting •  Measured by laser or white light scatter counter •  Counts the number of particles by estimated size •  4406:99 - Standard for particle count reporting •  Numbers reported by size ranges – o  Equal to or larger than 4 microns (≥4µm per ml) o  Equal to or larger than 6 microns (≥ 6µm per ml) o  Equal to or larger than 14 microns (≥ 14µm per ml) •  Reporting format: 19 / 17 / 14
#WindWebinar MacPherson Study L o n g e r L i f e Better Filtration Most Oil Filters Turbine Filters Magnetic Filtration
#WindWebinar Life  Cycle  Mul,pliers   for   Rolling  Element  Bearings   New  Oil  Cleanliness  Code  (ISO  4406)   20/17   19/16   18/15   17/14   16/13   15/12   14/11   13/10   12/9   11/8   10/7   Current  ISO  Cleanliness  Code   26/23   3 3.5 4 5 6 7.5 9 >10 >10 >10 >10 25/22   2.5 3 3.5 4 5 6 7 9 >10 >10 >10 24/21   2 2.5 3 4 5 6 7 8 10 >10 >10 23/20   1.5 2 2.5 3 3.5 4 5 6 8 9 >10 22/19   1.3 1.6 2 2.5 3 3.5 4 5 6 7 >10 21/18   1.2 1.5 1.7 2 2.5 3 3.5 4 5 7 10 20/17   Error 1.2 1.5 1.7 2 2.5 3 4 5 7 9 19/16   Error Error 1.2 1.5 1.7 2 2.5 3 4 6 8 18/15   Error Error Error 1.2 1.5 1.7 2 2.5 3 4.5 6 17/14   Error Error Error Error 1.2 1.5 1.7 2 2.5 3 5 16/13   Error Error Error Error Error 1.2 1.5 1.7 2 3.5 4 15/12   Error Error Error Error Error Error 1.2 1.5 1.7 2 2.5 14/11   Error Error Error Error Error Error Error 1.3 1.6 1.8 2 13/10   Error Error Error Error Error Error Error Error 1.2 1.5 1.8 ISO Code = 19 / 17 / 14 { 17 / 15 / 12New Code {
#WindWebinar Oil & Gas – Magnetic Filtration
#WindWebinar Oil & Gas – Mud Pumps
#WindWebinar
#WindWebinar
#WindWebinar Mud Pumps Baseline Before FilterMag (18 units) 22%17% 61%
#WindWebinar 22%17% 61% >150 Hours with FilterMag (18 units) 61% 6% 33% Mud Pumps
#WindWebinar Wind Turbine Gearboxes
#WindWebinar Wind Turbine Gearboxes
#WindWebinar Wind Turbine Bearings
#WindWebinar Wind Turbine Bearings
#WindWebinar Wind Turbine Gears
#WindWebinar Wind Turbine Gear Oil Objectives: 1) Cool 2) Clean 3) Dry Tools: 1) Heat Exchanger 2) Filtration 3) Seals/Breathers
#WindWebinar Wind Turbine Oil Filtration
#WindWebinar Magnetic Oil Filtration 1.  In Line Plumbed into oil lines 2.  Snap On Attached outside oil filter Water or chemical
#WindWebinar CT Line (for Spin-on Filters) XT Line (for Cartridge Style Filters) INDUSTRIAL PRODUCTS DIVISION
#WindWebinar Anatomy of a FilterMag
#WindWebinar Wind Turbine Trial 1) Gearboxes with history of oil analysis 2) Serial sampling after installation of FilterMags (1 Pair – FilterMag XT8 with 5µm Hydac filter) 3) ISO 4406 particle counts (Baseline, 1 month, 2 months, 4 months)
#WindWebinar 0   1000   2000   3000   4000   5000   6000   7000   8000   ≥4µ   ≥6µ   ≥14µ   Before  FilterMag   A;er  FilterMag   Turbine A – Before & After 89% Reduction 88% Reduction 77% Reduction Wind Turbine Trial
#WindWebinar 0   500   1000   1500   2000   2500   3000   3500   4000   4500   5000   ≥4µ   ≥6µ   ≥14µ   Before  FilterMag   A;er  FilterMag   86% Reduction 88% Reduction 90% Reduction Wind Turbine Trial Turbine A – Before & After
#WindWebinar 0   500   1000   1500   2000   2500   3000   3500   ≥4µ   ≥6µ   ≥14µ   Before  FilterMag   A;er  FilterMag   39% Reduction 47% Reduction 51% Reduction Wind Turbine Trial Turbine A – Before & After
#WindWebinar Average Particle Counts 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Baseline Month  1 Month  2 Month  4 Avg  ≥4µμ Avg  ≥6µμ Avg  ≥14µμ Before   AMer   19/17/14   17/15/12   Average  Reduc$ons   ≥4µm   78%   ≥6µm   79%   ≥14µm   77%   Wind Turbine Trial
#WindWebinar Life  Cycle  Mul,pliers   for   Rolling  Element  Bearings   New  Oil  Cleanliness  Code  (ISO  4406)   20/17   19/16   18/15   17/14   16/13   15/12   14/11   13/10   12/9   11/8   10/7   Current  ISO  Cleanliness  Code   26/23   3 3.5 4 5 6 7.5 9 >10 >10 >10 >10 25/22   2.5 3 3.5 4 5 6 7 9 >10 >10 >10 24/21   2 2.5 3 4 5 6 7 8 10 >10 >10 23/20   1.5 2 2.5 3 3.5 4 5 6 8 9 >10 22/19   1.3 1.6 2 2.5 3 3.5 4 5 6 7 >10 21/18   1.2 1.5 1.7 2 2.5 3 3.5 4 5 7 10 20/17   Error 1.2 1.5 1.7 2 2.5 3 4 5 7 9 19/16   Error Error 1.2 1.5 1.7 2 2.5 3 4 6 8 18/15   Error Error Error 1.2 1.5 1.7 2 2.5 3 4.5 6 17/14   Error Error Error Error 1.2 1.5 1.7 2 2.5 3 5 16/13   Error Error Error Error Error 1.2 1.5 1.7 2 3.5 4 15/12   Error Error Error Error Error Error 1.2 1.5 1.7 2 2.5 14/11   Error Error Error Error Error Error Error 1.3 1.6 1.8 2 13/10   Error Error Error Error Error Error Error Error 1.2 1.5 1.8 ISO Code = 19 / 17 / 14 { 17 / 15 / 12New Code { 50% Bearing Life Extension
#WindWebinar Life  Cycle  Mul,pliers   for   Gear  Boxes  &  Other   New  Oil  Cleanliness  Code  (ISO  4406)   20/17   19/16   18/15   17/14   16/13   15/12   14/11   13/10   12/9   11/8   10/7   Current  ISO  Cleanliness  Code   26/23   2.5 3 3.5 4 5 6.5 7 9 10 >10 >10 25/22   2 2.5 3 3.5 4 5 6 7.5 9 >10 >10 24/21   1.5 2 2.5 3 4 5 6 7 8 10 >10 23/20   1.3 1.5 2 2.5 3 3.5 4 5 6.5 8.5 10 22/19   1.1 1.3 1.7 2 2.5 3 3.5 4 5 5.5 8.5 21/18   1.1 1.3 1.4 1.6 2 2.5 3 3.5 4 5.5 8 20/17   Error 1.05 1.3 1.4 1.7 2 2.5 3 4 5.5 7 19/16   Error Error 1.1 1.3 1.5 1.7 2 2.5 3.5 4.5 6 18/15   Error Error Error 1.1 1.3 1.5 1.7 2 2.5 3.7 5 17/14   Error Error Error Error 1.1 1.3 1.5 1.7 2 2.5 3.5 16/13   Error Error Error Error Error 1.1 1.3 1.5 1.8 3 3.5 15/12   Error Error Error Error Error Error 1.1 1.4 1.5 1.8 2.2 14/11   Error Error Error Error Error Error Error 1.2 1.4 1.5 1.8 13/10   Error Error Error Error Error Error Error Error 1.1 1.3 1.6 ISO Code = 19/ 17/ 14 { 17 / 15 / 12New Code { 30% Gear Life Extension
#WindWebinar Magnetic Filtration Benefits 1) Help achieve target cleanliness codes (Extend normal life cycles) 2) Capture small ferrous particles as they are made (Slow down failure progression) (Extend Prediction – Failure interval) (Allows time to find and repair before failure) (Mitigate collateral damage – save other bearings) 3) Combined with on-condition monitoring (Significant cost savings)
#WindWebinar How to Determine the OpEx ROI of Investing in a Drive Train Monitoring Solution Assumptions •  Failure •  Repair can be made up-tower •  Generalized costs for power, man hours, crane cost, and CBM cost Catastrophic failure: (ReacƟve) Lost producƟon (assuming 30 days, $60/MWh, wind data from SCADA), 700 MWh:... $42,000 Man hours for technicians to clean turbine (100 @ $60/hr.): ........................................ $6,000 Man hours to replace gearbox (100 @ $60/hr.): ........................................................... $6,000 Crane rental: ........................................................................................................... $120,000 Replacement gearbox: ............................................................................................. $250,000 Total:........................................................................................................................ $424,000 Up-tower bearing replacement: (prevenƟve) Lost producƟon (2 weeks of curtailment @ 60% of capacity, assuming full wind): .........$8,400 Lost producƟon (3 days during bearing replacement): ......................................................... $0 Man hours to replace HSS bearing: 32 @ $60/hr.:..........................................................$1,920 Cost of CBM system per turbine (assuming 50 turbine site): .........................................$7,000 Cost of replacement bearing: ......................................................................................$20,000 Total:...........................................................................................................................$45,720 Cost Savings – Repair vs Replace [Source:    NREL]
#WindWebinar •  With 3 gearbox saves = 230% •  Saved well over $1,000,000 by the time you’re at 4 gearboxes. ROI for 50 Turbine Site with One Gearbox = ROI cost savings – (cost of CBM x # turbines) cost of CBM x # turbines) Case Study Cost Comparison of ReacƟve vs. PredicƟve Maintenance Cost for up-tower high speed shaŌ bearing replacements (4): ...................................$182,880 *Cost for replacing 4 gearboxes individually: ..........................................................$1,424,000 Man hours to replace gearbox (100 @ $60/hr.): .................................................$24,000 Crane rental:.....................................................................................................$400,000 Replacement gearboxes: ...............................................................................$1,000,000 EsƟmated Cost Savings...........................................................................................$1,237,280 $371,280 – ($7000 x 50) $7000 x 50) = ROI Cost Savings – Repair vs Replace [Source:    NREL]
#WindWebinar Michelle Froese Moderator Windpower Engineering & Development mfroese@wtwhmedia.com Randy Yount Vice President FilterMag rnyount@filtermag.com Doug Viner Mechanical Engineer Upwind Solutions doug.viner@upwindsolutions.com Reducing OpEx with Engineered Parts – Gearbox Life Extension Questions?
#WindWebinar Thank You q  This webinar will be available at www.windpowerengineering.com & email q  Tweet with hashtag #WindWebinar q  Connect with Windpower Engineering & Development q  Discuss this on EngineeringExchange.com

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How to Reduce OpEx With Engineered Parts

  • 1. #WindWebinar Reducing OpEx With Engineered Parts: Gearbox Life Extension
  • 2. #WindWebinar q  This webinar will be available afterwards at www.windpowerengineering.com & email q  Q&A at the end of the presentation q  Hashtag for this webinar: #WindWebinar Before We Start
  • 3. #WindWebinar Michelle Froese Moderator Windpower Engineering & Development Randy Yount Vice President FilterMag Doug Viner Mechanical Engineer Upwind Solutions Reducing OpEx with Engineered Parts – Gearbox Life Extension Meet your presenters…
  • 4. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions”
  • 5. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” Gearboxes not lasting 20 year design life à Need for condition monitoring
  • 6. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” Gearboxes not lasting 20 year design life à Need for condition monitoring Gearboxes, when they eventually fail, cause a lot of downtime.
  • 7. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” Gearboxes not lasting 20 year design life à Need for condition monitoring 1.  Temperature 2.  Vibration 3.  Borescope inspection…
  • 8. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions”
  • 9. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions”
  • 10. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions”
  • 11. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions”
  • 12. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!”
  • 13. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
  • 14. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
  • 15. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
  • 16. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
  • 17. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
  • 18. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3 
  • 19. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3  +25% +100% same effect
  • 20. #WindWebinar ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3  (1) This is easy for a WTG. Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” +25% +100% same effect
  • 21. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” “Gaah!” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/∆ 𝐿𝑜𝑎𝑑 )↑3  (1) This is easy for a WTG. (2) But this takes a big toll. +25% +100% same effect
  • 22. #WindWebinar Inner Race, “unwrapped” HSS-B Bearing Outer Race Rolling Elements
  • 23. #WindWebinar ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/ ∆ 𝐿𝑜𝑎𝑑 )↑3  “And then what?”
  • 24. #WindWebinar “Oh.” ​ 𝐿↓10   ~(​1/∆ 𝑅𝑃𝑀 )∗​(​1/ ∆ 𝐿𝑜𝑎𝑑 )↑3 
  • 26. #WindWebinar Image  Title Image  Title Case study available here: www.UpWindSolutions.com/blog/forensics-of-a-hss-bearing-failure
  • 27. #WindWebinar Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions” Gearboxes not lasting 20 year design life à Need for condition monitoring 1.  Temperature 2.  Vibration 3.  Borescope inspection 4.  Oil analysis (at last!) •  Can correlate oil particles with failure
  • 29. #WindWebinar Humans  can   resolve OEM  filter  can   remove
  • 30. #WindWebinar Mechanisms of Wear 1.  Abrasive Wear Particles between adjacent moving surfaces 2.  Adhesive Wear Metal to metal contact (insufficient lubricant film) 3.  Fatigue Wear Surfaces subjected to repeated stress 4.  Erosive Wear High velocity fluid (usually with particles) 5.  Corrosive Wear Chemically induced Water or chemical
  • 31. #WindWebinar Lubricant Contamination Internal - generated by friction and wear ©Paul  Filter  Corp  1995 External - water, dirt, and sand through gearbox seals or breather
  • 33. #WindWebinar Measuring Contaminants Human hair (~75 µm) at 100x Magnification Particles (~10µm)
  • 35. #WindWebinar Lubricating Film Thickness Machine Clearance Operating or Dynamic Clearance Machine clearance and operating or dynamic clearance are not equal. Operating clearance depends upon the load, speed and lubricant viscosity. A lubricant film separates moving surfaces to prevent metal-to-metal contact. 5µm 5µm ≤10µm
  • 36. #WindWebinar Elastohydrodynamic Lubrication ≤10µm•  Typical for rolling element bearings •  Elastic metal deformation •  Pressures reaching 350,000 psi •  Particles in oil flow into the film space •  Size depends upon operating conditions •  Trapped particles may indent the surfaces •  Cause pin point loading and stresses
  • 38. #WindWebinar Particle Counting / Reporting •  Measured by laser or white light scatter counter •  Counts the number of particles by estimated size •  4406:99 - Standard for particle count reporting
  • 39. #WindWebinar Particle Counting / Reporting Par$cles   per  Milliliter   Range   More   Up  To  &   Code   Than   Including   >28   2,500,000       28   1,300,000   2,500,000   27   640,000   1,300,000   26   320,000   640,000   25   160,000   320,000   24   80,000   160,000   23   40,000   80,000   22   20,000   40,000   21   10,000   20,000   20   5,000   10,000   19   2,500   5,000   18   1,300   2,500   17   640   1,300   16   320   640   15   160   320   14   80   160   13   40   80   12   20   40   11   10   20   10   5   10   Notes: 1)  Each code range is approximately double the previous range 2)  One code change could be 1 particle or ~4X the number of particles
  • 40. #WindWebinar Particle Counting / Reporting •  Measured by laser or white light scatter counter •  Counts the number of particles by estimated size •  4406:99 - Standard for particle count reporting •  Numbers reported by size ranges – o  Equal to or larger than 4 microns (≥4µm per ml) o  Equal to or larger than 6 microns (≥ 6µm per ml) o  Equal to or larger than 14 microns (≥ 14µm per ml) •  Reporting format: 19 / 17 / 14
  • 41. #WindWebinar MacPherson Study L o n g e r L i f e Better Filtration Most Oil Filters Turbine Filters Magnetic Filtration
  • 42. #WindWebinar Life  Cycle  Mul,pliers   for   Rolling  Element  Bearings   New  Oil  Cleanliness  Code  (ISO  4406)   20/17   19/16   18/15   17/14   16/13   15/12   14/11   13/10   12/9   11/8   10/7   Current  ISO  Cleanliness  Code   26/23   3 3.5 4 5 6 7.5 9 >10 >10 >10 >10 25/22   2.5 3 3.5 4 5 6 7 9 >10 >10 >10 24/21   2 2.5 3 4 5 6 7 8 10 >10 >10 23/20   1.5 2 2.5 3 3.5 4 5 6 8 9 >10 22/19   1.3 1.6 2 2.5 3 3.5 4 5 6 7 >10 21/18   1.2 1.5 1.7 2 2.5 3 3.5 4 5 7 10 20/17   Error 1.2 1.5 1.7 2 2.5 3 4 5 7 9 19/16   Error Error 1.2 1.5 1.7 2 2.5 3 4 6 8 18/15   Error Error Error 1.2 1.5 1.7 2 2.5 3 4.5 6 17/14   Error Error Error Error 1.2 1.5 1.7 2 2.5 3 5 16/13   Error Error Error Error Error 1.2 1.5 1.7 2 3.5 4 15/12   Error Error Error Error Error Error 1.2 1.5 1.7 2 2.5 14/11   Error Error Error Error Error Error Error 1.3 1.6 1.8 2 13/10   Error Error Error Error Error Error Error Error 1.2 1.5 1.8 ISO Code = 19 / 17 / 14 { 17 / 15 / 12New Code {
  • 43. #WindWebinar Oil & Gas – Magnetic Filtration
  • 44. #WindWebinar Oil & Gas – Mud Pumps
  • 47. #WindWebinar Mud Pumps Baseline Before FilterMag (18 units) 22%17% 61%
  • 48. #WindWebinar 22%17% 61% >150 Hours with FilterMag (18 units) 61% 6% 33% Mud Pumps
  • 54. #WindWebinar Wind Turbine Gear Oil Objectives: 1) Cool 2) Clean 3) Dry Tools: 1) Heat Exchanger 2) Filtration 3) Seals/Breathers
  • 56. #WindWebinar Magnetic Oil Filtration 1.  In Line Plumbed into oil lines 2.  Snap On Attached outside oil filter Water or chemical
  • 57. #WindWebinar CT Line (for Spin-on Filters) XT Line (for Cartridge Style Filters) INDUSTRIAL PRODUCTS DIVISION
  • 59. #WindWebinar Wind Turbine Trial 1) Gearboxes with history of oil analysis 2) Serial sampling after installation of FilterMags (1 Pair – FilterMag XT8 with 5µm Hydac filter) 3) ISO 4406 particle counts (Baseline, 1 month, 2 months, 4 months)
  • 60. #WindWebinar 0   1000   2000   3000   4000   5000   6000   7000   8000   ≥4µ   ≥6µ   ≥14µ   Before  FilterMag   A;er  FilterMag   Turbine A – Before & After 89% Reduction 88% Reduction 77% Reduction Wind Turbine Trial
  • 61. #WindWebinar 0   500   1000   1500   2000   2500   3000   3500   4000   4500   5000   ≥4µ   ≥6µ   ≥14µ   Before  FilterMag   A;er  FilterMag   86% Reduction 88% Reduction 90% Reduction Wind Turbine Trial Turbine A – Before & After
  • 62. #WindWebinar 0   500   1000   1500   2000   2500   3000   3500   ≥4µ   ≥6µ   ≥14µ   Before  FilterMag   A;er  FilterMag   39% Reduction 47% Reduction 51% Reduction Wind Turbine Trial Turbine A – Before & After
  • 63. #WindWebinar Average Particle Counts 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Baseline Month  1 Month  2 Month  4 Avg  ≥4µμ Avg  ≥6µμ Avg  ≥14µμ Before   AMer   19/17/14   17/15/12   Average  Reduc$ons   ≥4µm   78%   ≥6µm   79%   ≥14µm   77%   Wind Turbine Trial
  • 64. #WindWebinar Life  Cycle  Mul,pliers   for   Rolling  Element  Bearings   New  Oil  Cleanliness  Code  (ISO  4406)   20/17   19/16   18/15   17/14   16/13   15/12   14/11   13/10   12/9   11/8   10/7   Current  ISO  Cleanliness  Code   26/23   3 3.5 4 5 6 7.5 9 >10 >10 >10 >10 25/22   2.5 3 3.5 4 5 6 7 9 >10 >10 >10 24/21   2 2.5 3 4 5 6 7 8 10 >10 >10 23/20   1.5 2 2.5 3 3.5 4 5 6 8 9 >10 22/19   1.3 1.6 2 2.5 3 3.5 4 5 6 7 >10 21/18   1.2 1.5 1.7 2 2.5 3 3.5 4 5 7 10 20/17   Error 1.2 1.5 1.7 2 2.5 3 4 5 7 9 19/16   Error Error 1.2 1.5 1.7 2 2.5 3 4 6 8 18/15   Error Error Error 1.2 1.5 1.7 2 2.5 3 4.5 6 17/14   Error Error Error Error 1.2 1.5 1.7 2 2.5 3 5 16/13   Error Error Error Error Error 1.2 1.5 1.7 2 3.5 4 15/12   Error Error Error Error Error Error 1.2 1.5 1.7 2 2.5 14/11   Error Error Error Error Error Error Error 1.3 1.6 1.8 2 13/10   Error Error Error Error Error Error Error Error 1.2 1.5 1.8 ISO Code = 19 / 17 / 14 { 17 / 15 / 12New Code { 50% Bearing Life Extension
  • 65. #WindWebinar Life  Cycle  Mul,pliers   for   Gear  Boxes  &  Other   New  Oil  Cleanliness  Code  (ISO  4406)   20/17   19/16   18/15   17/14   16/13   15/12   14/11   13/10   12/9   11/8   10/7   Current  ISO  Cleanliness  Code   26/23   2.5 3 3.5 4 5 6.5 7 9 10 >10 >10 25/22   2 2.5 3 3.5 4 5 6 7.5 9 >10 >10 24/21   1.5 2 2.5 3 4 5 6 7 8 10 >10 23/20   1.3 1.5 2 2.5 3 3.5 4 5 6.5 8.5 10 22/19   1.1 1.3 1.7 2 2.5 3 3.5 4 5 5.5 8.5 21/18   1.1 1.3 1.4 1.6 2 2.5 3 3.5 4 5.5 8 20/17   Error 1.05 1.3 1.4 1.7 2 2.5 3 4 5.5 7 19/16   Error Error 1.1 1.3 1.5 1.7 2 2.5 3.5 4.5 6 18/15   Error Error Error 1.1 1.3 1.5 1.7 2 2.5 3.7 5 17/14   Error Error Error Error 1.1 1.3 1.5 1.7 2 2.5 3.5 16/13   Error Error Error Error Error 1.1 1.3 1.5 1.8 3 3.5 15/12   Error Error Error Error Error Error 1.1 1.4 1.5 1.8 2.2 14/11   Error Error Error Error Error Error Error 1.2 1.4 1.5 1.8 13/10   Error Error Error Error Error Error Error Error 1.1 1.3 1.6 ISO Code = 19/ 17/ 14 { 17 / 15 / 12New Code { 30% Gear Life Extension
  • 66. #WindWebinar Magnetic Filtration Benefits 1) Help achieve target cleanliness codes (Extend normal life cycles) 2) Capture small ferrous particles as they are made (Slow down failure progression) (Extend Prediction – Failure interval) (Allows time to find and repair before failure) (Mitigate collateral damage – save other bearings) 3) Combined with on-condition monitoring (Significant cost savings)
  • 67. #WindWebinar How to Determine the OpEx ROI of Investing in a Drive Train Monitoring Solution Assumptions •  Failure •  Repair can be made up-tower •  Generalized costs for power, man hours, crane cost, and CBM cost Catastrophic failure: (ReacƟve) Lost producƟon (assuming 30 days, $60/MWh, wind data from SCADA), 700 MWh:... $42,000 Man hours for technicians to clean turbine (100 @ $60/hr.): ........................................ $6,000 Man hours to replace gearbox (100 @ $60/hr.): ........................................................... $6,000 Crane rental: ........................................................................................................... $120,000 Replacement gearbox: ............................................................................................. $250,000 Total:........................................................................................................................ $424,000 Up-tower bearing replacement: (prevenƟve) Lost producƟon (2 weeks of curtailment @ 60% of capacity, assuming full wind): .........$8,400 Lost producƟon (3 days during bearing replacement): ......................................................... $0 Man hours to replace HSS bearing: 32 @ $60/hr.:..........................................................$1,920 Cost of CBM system per turbine (assuming 50 turbine site): .........................................$7,000 Cost of replacement bearing: ......................................................................................$20,000 Total:...........................................................................................................................$45,720 Cost Savings – Repair vs Replace [Source:    NREL]
  • 68. #WindWebinar •  With 3 gearbox saves = 230% •  Saved well over $1,000,000 by the time you’re at 4 gearboxes. ROI for 50 Turbine Site with One Gearbox = ROI cost savings – (cost of CBM x # turbines) cost of CBM x # turbines) Case Study Cost Comparison of ReacƟve vs. PredicƟve Maintenance Cost for up-tower high speed shaŌ bearing replacements (4): ...................................$182,880 *Cost for replacing 4 gearboxes individually: ..........................................................$1,424,000 Man hours to replace gearbox (100 @ $60/hr.): .................................................$24,000 Crane rental:.....................................................................................................$400,000 Replacement gearboxes: ...............................................................................$1,000,000 EsƟmated Cost Savings...........................................................................................$1,237,280 $371,280 – ($7000 x 50) $7000 x 50) = ROI Cost Savings – Repair vs Replace [Source:    NREL]
  • 69. #WindWebinar Michelle Froese Moderator Windpower Engineering & Development mfroese@wtwhmedia.com Randy Yount Vice President FilterMag rnyount@filtermag.com Doug Viner Mechanical Engineer Upwind Solutions doug.viner@upwindsolutions.com Reducing OpEx with Engineered Parts – Gearbox Life Extension Questions?
  • 70. #WindWebinar Thank You q  This webinar will be available at www.windpowerengineering.com & email q  Tweet with hashtag #WindWebinar q  Connect with Windpower Engineering & Development q  Discuss this on EngineeringExchange.com