how to reduce opex with engineered parts

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Reducing OpEx With Engineered Parts:

Gearbox Life Extension

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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

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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…

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Part 1: Gearbox Challenges & Solutions “End-Users Face Long-Term Hurdles, Seek Cost-Effective Solutions”

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Gearboxes not lasting 20 year design life à Need for condition monitoring

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Gearboxes, when they eventually fail, cause a lot of downtime.

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1.  Temperature 2.  Vibration 3.  Borescope inspection…

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“Gaah!”

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“Gaah!”

𝐿↓10  ~(1/∆𝑅𝑃𝑀 )∗(1/∆𝐿𝑜𝑎𝑑 )↑3 

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“Gaah!”

𝐿↓10  ~(1/∆𝑅𝑃𝑀 )∗(1/∆𝐿𝑜𝑎𝑑 )↑3 

+25%

+100% same effect

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𝐿↓10  ~(1/∆𝑅𝑃𝑀 )∗(1/∆𝐿𝑜𝑎𝑑 )↑3  (1) This is easy for a

WTG.


“Gaah!”

+25%

+100% same effect

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“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

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Inner Race, “unwrapped”

HSS-B Bearing

Outer Race

Rolling Elements

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𝐿↓10  ~(1/∆𝑅𝑃𝑀 )∗(1/∆𝐿𝑜𝑎𝑑 )↑3 

“And then what?”

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“Oh.”

𝐿↓10  ~(1/∆𝑅𝑃𝑀 )∗(1/∆𝐿𝑜𝑎𝑑 )↑3 

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Cracked outer race

HSS-C Bearing

Pitted & deformed balls

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Image Title Image Title Case study available here:

www.UpWindSolutions.com/blog/forensics-of-a-hss-bearing-failure

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1.  Temperature 2.  Vibration 3.  Borescope inspection 4.  Oil analysis (at last!)

•  Can correlate oil particles with failure

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Humans can resolve

OEM filter can remove

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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

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Lubricant Contamination

Internal - generated by friction and wear

©Paul Filter Corp 1995

External - water, dirt, and sand through gearbox seals or breather

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Particle Sizes

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Measuring Contaminants

Human hair (~75 µm) at 100x Magnification

Particles (~10µm)

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Typical Clearances Clearance in Microns Component

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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

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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

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Elastohydrodynamic Lubrication

≤10µm

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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

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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

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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

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MacPherson Study

Longer

Life

Better Filtration

Most Oil Filters

Turbine Filters

Magnetic Filtration

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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

Curren

t ISO

Clean

liness C

ode

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 / 12 New Code {

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Oil & Gas – Magnetic Filtration

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Oil & Gas – Mud Pumps

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Mud Pumps Baseline Before FilterMag (18 units)

22% 17%

61%

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22% 17%

61%

>150 Hours with FilterMag (18 units)

61%

6%

33%

Mud Pumps

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Wind Turbine Gearboxes

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Wind Turbine Bearings

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Wind Turbine Gears

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Wind Turbine Gear Oil

Objectives: 1) Cool 2) Clean 3) Dry

Tools: 1) Heat Exchanger 2) Filtration 3) Seals/Breathers

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Wind Turbine Oil Filtration

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Magnetic Oil Filtration 1.  In Line

Plumbed into oil lines

2.  Snap On Attached outside oil filter Water or chemical

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CT Line (for Spin-on Filters)

XT Line (for Cartridge Style Filters)

INDUSTRIAL PRODUCTS DIVISION

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Anatomy of a FilterMag

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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)

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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

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0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

≥4µ ≥6µ ≥14µ


86% Reduction

88% Reduction

90% Reduction

Wind Turbine Trial Turbine A – Before & After

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0

500

1000

1500

2000

2500

3000

3500

≥4µ ≥6µ ≥14µ


39% Reduction

47% Reduction

51% Reduction

Wind Turbine Trial Turbine A – Before & After

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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

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Rolling Element Bearings


20/17 19/16 18/15 17/14 16/13 15/12 14/11 13/10 12/9 11/8 10/7

Curren

t ISO

Clean

liness C

ode

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 / 12 New Code {

50% Bearing Life Extension

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Gear Boxes & Other


20/17 19/16 18/15 17/14 16/13 15/12 14/11 13/10 12/9 11/8 10/7

Curren

t ISO

Clean

liness C

ode

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 / 12 New Code {

30% Gear Life Extension

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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)

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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: (Reac!ve)

Lost produc!on (assuming 30 days, $60/MWh, wind data from SCADA), 700 MWh: ... $42,000Man hours for technicians to clean turbine (100 @ $60/hr.): ........................................ $6,000Man hours to replace gearbox (100 @ $60/hr.): ........................................................... $6,000Crane rental: ........................................................................................................... $120,000Replacement gearbox: ............................................................................................. $250,000Total: ........................................................................................................................ $424,000

Up-tower bearing replacement: (preven!ve)

Lost produc!on (2 weeks of curtailment @ 60% of capacity, assuming full wind): .........$8,400Lost produc!on (3 days during bearing replacement): ......................................................... $0Man hours to replace HSS bearing: 32 @ $60/hr.: ..........................................................$1,920Cost of CBM system per turbine (assuming 50 turbine site): .........................................$7,000Cost of replacement bearing: ......................................................................................$20,000Total: ...........................................................................................................................$45,720

Cost Savings – Repair vs Replace

[Source: NREL]

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•  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 Reac!ve vs. Predic!ve MaintenanceCost for up-tower high speed sha" 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

Es!mated Cost Savings ...........................................................................................$1,237,280

$371,280 – ($7000 x 50)

$7000 x 50)= ROI

Cost Savings – Repair vs Replace

[Source: NREL]

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Michelle Froese Moderator Windpower Engineering & Development [email protected]

Randy Yount Vice President FilterMag [email protected]

Doug Viner Mechanical Engineer Upwind Solutions [email protected]

Reducing OpEx with Engineered Parts – Gearbox Life Extension

Questions?

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Thank You q  This webinar will be available at

www.windpowerengineering.com & email

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