Download - Stefan Bill 190511
REWITEC NanocoatingDurable Wear Protection and Reconditioning
for high loaded Gearboxes and Bearings
in Windturbines
All Energy 2011
REWITEC presents the unique possibility
to coat, to protect and to recondition new and worn outmetal surfaces!
REWITEC-Technology
Replacement of the friction pair „metal-metal“ by „meta l ceramic-metal ceramic“
Advantages:
Reduction of abrasion and wear of rubbing metal surfaces
Coating process during system is running, without down time
Obvious increase and smoothening of load carrying areas
Prolongation of gearbox and bearing life time
Targets of REWITEC Technology
Reduction of friction, vibration and noise
Cost saving by:
Extension of lifetime Reduction of repairs Prolongation of maintenance intervals Bridging of delivery times/ Planned exchange possible
Improvement of efficiency:
Savings of energy and fuel up to 11 %
Reduction of emissions (Diesel soot, CO2, HC und NOx)
Emergency running properties in case of oil loss
Advantages of REWITEC Technology
The microsection shows the running surface of a ball bear ing of a planet gear box after 250 hours of operation in an area of fatigue. The Rewitec Coating up to 30µm could be obviously recognized.
Microsection of a ball bearing surface
Rewitec Coating
Origin metal
Test on 2 gears of company Tandler
HL HWS A1 3.1 IIITests with Rewitec
0
20
40
60
80
100
120
140
10:3
0:44
12:3
5:32
14:4
0:12
16:4
5:32
18:5
0:28
20:5
5:53
23:0
0:39
01:0
5:49
03:1
0:57
05:1
5:33
07:2
0:55
09:2
5:50
11:3
0:54
13:3
5:58
15:4
1:03
17:4
6:07
19:5
1:11
21:5
6:15
23:5
9:45
02:0
6:02
04:1
1:21
06:1
5:56
08:2
1:03
10:2
6:11
12:3
1:19
14:3
6:26
16:4
1:34
18:4
6:42
20:5
0:41
22:5
5:22
01:0
0:54
03:0
5:48
05:1
0:58
07:1
5:56
09:2
0:58
11:2
5:57
13:3
1:01
Time in hms
Tem
pera
ture
in °C
[°C] 23/1
[°C] 23/2
[°C] 23/3
[°C] 23/4
[°C] 28/5
[°C] 27/6
[°C] 27/7
[°C] 27/8
[°C] 27/9
Temperature trend of the 2 Tandler gears with 2 differen t oils with and without Rewitec- Temperature reduction of 6 – 10 ºCelsius
Temperature Oil 1 107,7 ºCTemperature Oil 2 103,5º C
Fill in of the oil with the Rewitec concentrate at the start temperature of 113,5º Celsius
Bearing load test comparisenOEM grease versus REWITEC treated OEM grease in a 2 0.000 N bearing load test
Temperature measurement at axial bearings type 81105: Results: Bearings with untreated grease failed after about 7 hours load test. Bearings withRewitec treated grease did not fail for over 19 hours. The bearings running with Rewitec lasted for around 2.7 times longer.
Bearing Load Test
0
20
40
60
80
100
120
1 423 845 1267 1689 2111 2533 2955 3377 3799 4221 4643 5065 5487 5909 6331 6753 7175 7597 8019
Time/ sec.
Tem
pera
ture
/ deg
ree
Cel
sius
Fett rot
Fett rot
Fett rot mit Rewitec
Fett rot mit Rewitec
Complete Failure
--- Grease without
--- Rewitec
--- Grease treated with
--- Rewitec
Bearing load test comparisenOEM grease versus REWITEC treated OEM grease in a 2 0.000 N bearing load test
Friction measurement at axial bearings type 81105: Results: Bearings with untreated grease failed after about 7 hours load test. Bearings with Rewitec treated grease did not fail for over 19 hours. The bearings running withRewitec lasted for around 2.7 times longer.
Zerstörung der Lager
Bearing Load Test
-5
0
5
10
15
20
25
30
35
40
1 352 703 1054 1405 1756 2107 2458 2809 3160 3511 3862 4213 4564 4915 5266 5617 5968 6319 6670 7021 7372 7723 8074
Time/sec.
Load
/Nm
Fett rot
Fett rot
Fett rot mit Rewitec
Fett rot mit Rewitec
Complete Failure
--- Grease without
--- Rewitec
--- Grease treated with
--- Rewitec
Photos of the raceways of two ball bearings after 5 0 hours of operation in a range of fatigue
Bearing type: No. 6205 (d=25mm D=52mm)Lubricant: Special bearing greaseOperating time: 50 hoursRotational speed: 500 min -1
Nominal load: 5000 N radial (range of fatigu e)
This ball bearing does not show any wear. The runni ng surface of the balls clearly shows a wear resistant coating.
Load Test of Ball Bearings
This ball bearing shows damage due to wear and tear. The running surface of the balls clearly shows pitting
Bearing type: No. 6205 (d=25mm D=52mm)Lubricant: Special bearing grease treated with REWITECOperating time: 50 hoursRotational speed: 500 min -1
Nominal load: 5000 N radial (range of fatigu e)
running surfacesof the balls
Industry:
Gears
Combustion engines Compressors
Bearings
Hydraulic pumps/ -motors
Vacuum pumps Chain drives
Gear racks, pinions
Range of REWITEC applications
Utility vehicles:
Gasoline- and diesel engines Gears Rear axles, differentials Universal shafts Compressors Roller-, slide bearings
Range of REWITEC applications
Railways:
Diesel engines Gears Compressors Bearings
Treatment of 2 drill head gears at Volkswagen engines produktion line in Salzgitter
Problem:Short lifetime, extreme high costs in case of idleness and breakdown (>25.000,-€), higher oiltemperature (51°C). Emergency run problems due to oil le akage.
Result: Oil and oil filter are clean with nearly no metal particles. After REWITEC coating oiltemperature was reduced by about 6°C to max. 45°C. Due to a system leakage drillingemulsion went into the gearbox. The REWITEC Nanocoating prevented the system againstdamages.
Savings of about 100,000 Euro p.a.Treatment costs are 149 Euro per gearbox
Coating of a wind turbine gearbox of a Tacke TW250
Goal of application: - Rebuilding of worn out teeth surfaces- Reduction of grey stoking- Protection against further wear and prolongation of life time
Results after about 700 hours operating time:- The teeth surfaces are much smoother and more shiny (replicas before and after) - The damages are without sharp edges- The coated teeth surfaces had a higher electrical resistance of about 50 Ω
Savings of about 80,000 EuroTreatment costs are 1,200 Euro
Coating and analyses of a 600KW wind turbine gearbox
Goal of application: - Reduction of grey staining- Protection against further wear and prolongation of life time
Condition after 64 days operating time:- The teeth surfaces are much smoother and more shiny (replicas before and after) - The damages are without sharp edges- The coated teeth surfaces had a higher electrical resistance of about 100 Ω
Savings of about 150,000 EuroTreatment costs are 2,560 Euro
Coating and analyses of 1MW Windturbine gearbox
Before Rewitec treatment at 17.03.2009 After Rewitec treatment at 23.09.2009
Results after 150 days: - The teeth surfaces are much smoother and more shiny (replicas before and after) -3D-Topografie-Analyses of NanoFocus AG with µsurf-Technology proves that the surface smoothening/
refinement and results in a 18-times bigger load carrying tooth area!
Topography
Coating of a AN Bonus 1MW wind turbine gearbox
Goal of application: - Rebuilding of worn out teeth surfaces and Reduction of grey stoking- Anaylsis via µ-Sen CMS- Protection against further wear and prolongation of life time
Results after about 700 hours operating time:- The teeth surfaces are much smoother and more shiny (replicas before and after) - The coated teeth surfaces had a higher electrical resistance of about 50 Ω- µ-Sen CMS shows a 20% reduced damage frequency and noise in the system
Coating of a AN Bonus 1MW wind turbine generator beari ng
Goal of application: - Wear protection of generator bearing, due to use of Rewitec coating grease in December 2008- Anaylsis via µ-Sen CMS (Condition Monitoring System)- Protection against further wear and prolongation of life time
Results after 6 months: -µ-Sen CMS shows clearly the stop of the progressive increase of the damage frequency in generator bearing
We have treated already about 600-700 wind turbines:
AN Bonus 1,0MW, 1,3MWDeWind D4, D6GE 1,5MWGamesa G47HSW1000 1,0MWNEG Micon NM48, NM60, NM82Nordex S70, S77, N90, N54Repower 5MSuzlon different typesTacke TW250, TW600, 1.5sVestas V20, V25, V39, V47, V66, V80
Already treated wind turbines
26
Wind Energy Update on Wind Mill O & M
Press ReleaseNew report defines true cost of wind turbine operatio ns & maintenance
March 1, 2010
“Gearboxes are still the Achilles’ heel for the wind industry, and can cost up to $500,000 to fix due to the high cost of replacement parts, cranes (which can cost $75,000-$100,000), post installation testing, re-commissioning and lost power production,” says one long-term veteran O&M technician.
Economy of the Nano Coating in case of breakdown
6,2 daysAmortization time due to down time
4,3 months**Amortization time dueto longer life time
6.400,- EuroCosts of treatment
1.028,- EuroCommission per day
9,5 Ct/ kWhCommission
10.822 kWh Output per day
3.950.000 kWh *Output per year
1.500 kWTurbine Power
*Output related to referenz location with a medium yearly wind speed of 5,5m/s** Prolongation of life time with a bank rate of 6% and costs of a new gearbox 300.000,- Euro
Economy of the Treatment „WPD“
5,9 Mio. EuroExpected cost reductions per year
3.511 GWh** Energy Production per year (GWh)
50%Expected reduction of gearbox replacements
15 – 20%Increase of net profit
2,52 Mio. EURTreatment costs Rewitec per year
16,78 Mio. EURTotal downtime costs per year
2,63 Mio. EUR**** Downtime costs per year
14,15 Mio. EUR*** Gearbox replacement costs per year
316 Mio. Euro *** Revenues per year (Euro)
1.179 MW* Total Power
* Without Enercon, Status 2009** Production related to average wind speed of 6,5m/s, 9 Ct/kWh feed in tarif*** Expected is 1 gearbox replacement in 10 years with 120 TEUR per MW**** Expected is 30 days downtime für gearbos replacementl
• Surfaces pictures, endoscopies
• Oil analyses
• Measurements of the electrical resistance of the coated s urfaces
• Imprints of tooth- and bearing surfaces
• Condition Monitoring
Proof of REWITEC Technology
28. Innovation Award of German Economy Wirtschaft
0n 19th of January 2008 REWITEC was announced as finalist of 28. German Innovation Award 2007. The Award for one of the best innovations in 2007 was presented to REWITEC from the Ministry of Economics and Technology in the „Old Opera“ in Frankfurt.
1st Husum WindEnergy Award 2009
REWITEC was Finalist of the 1st HUSUM WindEnergy Award 2009. REWITEC‘s„Nanocoating for Tribosystems“ is belonging now to one of the best innovations forwind industry.
Present cooperations and customers
HatlapaMarine EquipmentPeterson & Söhne
ThyssenKruppZollern
Leonhardt & Blumberg
Thank you for your attention !
Stefan Bill, Managing Director
Mobil: +49(0)173/6790063
Tel: +49(0)6441/44599-0