yields profit!wind turbinepreventative maintenance

preventative maintenance

yields profit!

reduced wear metalsAn increase or reduction of metal content over a period of time is an important factor in terms of the condition of a gearbox; free metals (Fe) in gear oil is very damaging. Apart from ordinary online – and possibly offline – filters and magnetic plugs, magnetic oil filters can also be installed for better visual inspection and collection of wear debris.Even new gearboxes have abrasive metals in circulation; the harmful process starts here. Sudden emergency stops influence the amount of metals that are constantly, and normally, released.

Almasol Molybdenum Disulfide Graphite Fluorocarbon (PTFE)

Maximum service temp.1* 1,038°C 343°C 426°C 260°C

Load capacity psi 2* 400.000 400.000 80.000 5.000

Chemical reaction No Yes Yes No

Disadvantages None Creates molybdenum trioxide, Creates galvanism, No load capacity which acts as an abrasive and corrodes metals and and builds on itself, builds on itself; affects tolerances builds on itself, affects affects tolerances tolerances

Note 1* An uneven metal surface creates “hot spots” during loading frequently exceeding 538°C.

Note 2* Metal deforms at 175,000 psi.

Lubrication Engineers oils and greases with Almasol®, Duolec™, Quinplex® and Monolec® additives provide extra protection against wear and shock loads. These patented additives are only available in lubricants from Lubrication Engineers, Inc. The LE research laboratory in the USA has been developing enhanced lubricants since 1951. Its latest gear additive tech-nolog y, DUOLEC, was launched in 2005 after 25 years of development. For over 20 years, Lubrication Engineers has successfully lubricated wind turbine gearboxes, bearings and open gears. We are Lubrication Engineers – “Leaders in Lubricants” – and we are well-prepared for a future in the wind turbine industry.

Wind turbine technology has developed quickly, and today’s demands on lubricants and equipment in-crease due to optimised production requirements. High priority is given to the cost of usage, not purchases. Investment in high quality lubricants yields profits by increasing the lifespan of the equipment and reducing downtime and the need for expensive spare parts. Where conventional oils surrender to viscosity and standardised additive packages, Lubrication Engineers has its own exclusive protection. In this sense, LE is unique and has successful case studies to prove it.

All temperatures are collected by OEM’s service technicians and wind turbine owners. Lubrication Engineers does not collect any data for reasons of integrity. Individual gearboxes may differ from the above averages.

Above, part of magnetic core of filter

Tip! Invest in magnetic oil filters for visual inspection & collection of wear metals.

Less friction-Lower temperatures & Less wearLess friction means lower temperatures and less wear.

•Gearbox oil temperatures reduced by -5°C to -12°C

•Gearbox bearing temperatures reduced by -5°C to -8 °C

•Generator bearing temperatures reduced by -5°C to -17°C

LE lubricants increase equipment life and reduce spare part requirements.

Open gearsPyroshield® 5180

Main bearingsAlmagard® 3751 alternatively Almaplex® 1299 Pitch bearings

Almagard® 3751 alternatively Almaplex® 1299

HydraulicsMonolec® 6520

Generator bearingsAlmagard® 3751 alternatively Almaplex® 1299

GearboxAlmasol® 605 (ISO 320)alternatively Duolec™ 1606 (ISO 320)or Synolec® 9832 (ISO 320)

lower temperatureAll gearboxes and bearings are individual and react differently. This is due to construction, historical wear, alignment and current load. Temperature reductions in gearboxes and bearings sometimes occur instantly or over a longer period of time. However, most follow the standard, and lower friction means lower temperatures and less wear.

Tip! Log the wind turbine’s maximum temperature before changing the oil. Zero the log thereafter and record new maximum temperature after full production, compare and log the performance, check thermostats and fans.

oil analysisOil analysis is not an exact science but provides an important trend over time. Particle-counting technology provides online results on increased or reduced number of particles (ISO cleanliness codes) for the oil. There is a great risk for contamination during manual oil tests; particles that are measured are often the size of bacteria.

Tip!Perform oil analysis on the old oil that is to be replaced in the gearbox. Then perform an analysis on oil that has been used for one day; important as a reference. Follow-up with oil checks every three months.

water separationChanges in temperature create condensation inside gearboxes. This moisture, if coupled with a blocked air filter, can be catastrophic for lubricants and gearboxes. However, LE oil separates from water, which is therefore easier to remove by draining.

Tip!

Install an oil sight glass in the base of the gearbox so that water contamination is visible and can be periodically drained off.

production and management supportLubrication Engineers works successfully in close partnerships whilst applying the following procedure:

•Flushing of gearboxes and changing to LE lubricants•Installationofcentrallubricationsystemswith Almasol greases in all bearings•Loggingofmaximumtemperaturesforgearboxes and bearings•Installationofmagneticoilfilters•Regularoilanalysis

Changing of mechanical vents and calibration of parameters for oil cooling and pumps is required in some cases. This particular working method offers better control and more efficient wind turbines.

almasol®LE Almasol gear oil (605), Almagard (3751) and Almaplex (1299) greases, and Pyroshield Syn Open Gear Grease (5180) all contain Almasol.A highly refined soft powder, Almasol is a solid anti-wear additive derived from aluminium, magnesium and silicate. Almasol particles are tiny, 0.5-2 microns; 8,000 of them would fit on the full stop at the end of this sentence. Almasol is attracted to metal and creates a protective “glove” around all moving parts. Almasol withstands acid attack and high temperatures up to 1,038°C and has a load carrying capacity of up to 400,000 psi; metal deforms at 175,000 psi. These features prevent metal-to-metal contact.

Almasol separates metal surfaces.

monolec®LE Monolec R & O Compressor/Turbine Oil (6401-6407) contains Monolec.Monolec provides molecular oil film lubrication. The Monolec molecule is attracted to metal. A highly rein-forced oil film protects against friction, heat and wear, normally in hydraulics, compressor, turbine, motor and industrial oils. The Monolec molecule’s capacity for metal attraction makes it an outstanding flushing oil; it loosens any deposits in the process. In radioactive wear tests Monolec has, in comparison with conventional oils, shown 24.2% less wear.

quinplex®LE Almagard (3751) and Almaplex (1299) greases contain Quinplex.It is integrated with the LE bearing greases to improve the cohesion or coupling of the grease base with the oil, and therefore considerably increase its mechanical stability. The grease does not separate (bleed), and therefore does not “harden”; the lubricant does not leak and also gains a higher heat stability and resistance to water.

le’s unique, exclusive

proprietary additivesduolec™LE Duolec Vari-Purpose Gear Lubricant (1606- 1609) contain Duolec. Duolec reduces wear by minimising friction and by strengthening the oil film where loads create metal-to-metal contact. Duolec contains no solid lubricants, only soluble additives that do not build up or drop out of the gear oil. Duolec is thermally activated at two stages to create double protection. When the load increases, the EHD (Elasto - Hydro - Dynamic) protection and wear-reducing components react beyond that of ordinary patented EP-packages (Extreme Pressure). If the load is increased further, DUOLEC’s secondary protection is fully activated. Duolec’s protection can therefore be local, during a short time period, and handle 300°C to 1,000°C.

Duolec: ASTM wear tests show 9% lower wear when only Duolec is added to a base oil. SRV tests show 25% less friction with Duolec™.

open Gear Lubricant

pyroshield®LE Pyroshield Syn Open Gear Grease (5180) is a unique lubricant for open gears.It lowers the temperature by 5-15%, reduces lubricant consumption by up to 80%, has no dropping point and has a Timken Load of 90 lbs (40.8 Kg) according to ASTM D 2509.Pyroshield contains no asphaltic products or lead and is environmentally safe, it contains Almasol and is used successfully in the mining industry, where extreme shock loads in open gears are common.