PREVENTATIVE MAINTENANCE
Lubrication Engineers oils and greases with Almasol®, Duolec ™ , Quinplex® and Monolec® additives provide extra protection against wcar and shock loads. These patented additives are only available in lubricants from Lubrication Engineers, Jnc. The LE research laboratory in the USA has been developing enhanced lubricants since 1951. Its latest gear additive tech nology, DUOLEC, was launched in 2005 after 25 years of development. For over 20 years, Lubrication Engineers has successfully lubricated wind turbine gearboxes, bearings and opeu gears. We are Lubrication Engineers - "Leaders in Lubricants" - and we are well-prepared for a future in the wind turbine industry.
Wind rurbine technology has developed quickly, and toda)"s demands on lubricams and equipment in crease due to optimised production requirements. High priorityis given to the cost ofusage, 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 pans. Where convemional 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 ~jI GElv!'s service tedmicians and wind IUrbine oamer:;. Lubrication Engineers cfoes not collect alley dafa for,.eetsmfs oJ ir1f.U:.f1ity. Individualgearboxes may dijleffium tbe above averages.
R DUCED \'\!'EAR METAl An increase or reduction of metal contem over a period of time is an importam factor in terms of the condition of agearbox; free metals (Fe) in gear oil is very damaging. Apart from ordinary online - and possibly omine - 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 infiuence the amoumof metals that are constantly, and normally, released.
Above, parr oj magnetic core offiller InveSi in magnetiC oil.filtersfor visual in:.opection & collection ofwear me/als.
M.aln be~rings 3751 alternatively A101aplex® 1299 A101agard~
Pitch bearing:> A1magard@ 3751 alternatively A1maplex® 1299
GeneratOr bearings A1magard® 3751 alternatively A1maplex® 1299 Gearbox
Ahnasol® 605 (ISO 320)
alternatively Duolec"" 1606 (ISO 320)
or Synolec®9832 (ISO 320)
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·Mp·RATU
All gearboxes and bearings are individual and react differemly. 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 (ime. However, most follow the standard, and lower tiicrion means lower temperatures and less wear.
Log {be wind tu.rbine's maximu.m temperature be/ore dmnging the oil. Zero the log (berea/te,. and record new mel. 'I::imum teitlpemJu:l'e ajtrJrlufl production, cOlllpcwe and log tbe perfoJ'mance, check Ibemwslars andfans
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Hyclraulics Monolec® 6520 Open gears Pyroshield® 5180
WATER SEPARATtDN Changes in temperature create condensation inside gearboxes. This moisture, if coupled with ablocked air filter, can be catastrophic for lubricants and gearboxes. However, LE oil separates from water, which is therefore easier to remove by draining.
InS/al! all oil Sight glass in 10 base ol!bf! gr!(lP"box so thai warer colllamination is visible and am be pel'iodicatty dmilled off. PO' JON AND MANAGEM NT SUprORT Lubrication Engineers works successhilly in dose pa[tnecships whilst applying the foUowing procedure:
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Oil analysis is not an exact science but proVides an important trend over time. Particle-counting technology provides online results on increased or reduced nu mber of particles (ISO c1eanl iness codes) for the oil. There is agreat risk for contamination during manual oil tests; particles that are measured are often the size of bacteria.
• Flushing of gearboxes and changing to LE lu bricanrs • Installation of central lubrication systems with A1masol greases in all bearings • Logging of maximum temperawres for gearboxes and bearings • Installation of magnetiC oil fihers • Regular oil analysis
PeJ!orm oil analysis on the old oilibat is 10 be I''eplacedin tbegearbo.x. TlJeJlpeljQl'f1I em analysis on oi/. Ibta ha.s been u~d for one day; important as a re!el'eli<;e. FollollJ-up with oft checks eveJ)' tbree months.
Changing of mechanical venrs 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.
l.f:: ltiblicallJs iJ'U;re:tlSe equipment hfe and reduce spare parl1l!'flfil'emems.
LE'S UNICWE, EXCLUSIVE
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LE Almasol gear oil (60S), Almagard (3751) and Almaplex (1299) greases, and Pyroshield Syn Open Gear Grease (5180) all contain A1masoL A highly refined soft powder, A1masol is a solid ami-wear additive delived linIn alULninium, magnesium and silil'ate.Almasol panicles are tiny, 0.5-2 microns; 8,000 of them would fit on the full swp a! the end of this sentence. AJmasol is attracted to metal and creates a protective "glove" around all moving pans. A1masol withstands acid attack and high temperatures up to 1,038°C and has aload carrying capaciry of up to 400,000 psi; metal deforms at 175,000 psi. These features prevent metal-[o·metal contact.
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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 nm build up or drop Ollt of the gear oil. Duolec is thermally activated aL IWO stages [0 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, DUOLECs secondary protection is fully activated. Duolec's protection can therefore be local, during a shon time period, and handle 300°C to 1,000°e.
Almasni i"(!/Xlrates metal SW.1l]Ces.
MONO LE Monolec R & 0 CompressorlTurbine Oil (6401·6407) contains Monolec. Monolec proVides molecular oil film lubJication. The Monolee molecule is auracted to metal. Ahighly rein forced oil film protects against friction, heal and wear, normally in hydraulics, compressor, turbine, motor and industlial oils. The Monolec molecule's capacil\, for metal auraction makes it an outstanding flushing oil; il loosens any deposits in the process. In radioactive wear tests Monolec has, in comparison wjth conventional oils, shown 24.2% less wear.
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LEAlmagard (3751) andAimaplex (1299) greases contain QUinp!ex. It is integrated wilh the LE bearing greases 10 improve the cohesion or coupling of the grease base with the Oil, and therefore considerably increase its mechanical stability. 11le 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.
Duol : ASrM we(ll' te.'i/S show 9% lower wear when
oni)' Duok'f; is add 'd 10 a I-xlSe oil. SRV tests sbow 25% lessfriction with DlI{)t~ "'.
OF PYROSHIEL LE Pyroshield Syn Open Gear Grease (5180) is a unique lubricant for open gears. It lowers the temperature by 5-15%, reduces lubricant consumption b)' up to 80%, has no dropping point and has a Timken Load of 90 Ibs (40.8 Kg) according to ASTM D 2509. Pyroshield contains no asphaltic pmducts or lead and is environmentally safe, it contains Almasol and is llsed successfully in Ihe mining industry, where extreme shock loadS in open gears are common.
LUBRICATIONENGINEERS,@c:!g. The L 'bricatio He iability Source'~ Lubrication Engineers Sweden Wind Turbine Co,ordinalor Patrik Madsen Phone + 4640-52 00 54 Mobile + 46708-520 220 E·mail:
[email protected]
Lubrication Engineers International A.G. E-mail:
[email protected] www.le-international.com www.le-inc.com