Recommendation to Comply with the Requirements in the Technical Criteria for the Danish Approval Scheme for Wind

Turbines

Gearboxes

Section 5 Lubrication

February 2002

Energistyrelsen The Danish Energy Agency

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Table of contents
Introduction................................................................................................................................ 3 1. Objective............................................................................................................................... 4 2. Climate, operating conditions and loads............................................................................... 4 3. Housing and bearings............................................................................................................ 4 4. Gear wheels and shafts ......................................................................................................... 4 5.0 Lubrication...................................................................................................................... 5 5.1 Lubrication regimes ........................................................................................................ 5 5.1.1 Full hydrodynamic conditions ................................................................................. 5 5.1.2 Mixed film conditions.............................................................................................. 5 5.1.3 Boundary film conditions ........................................................................................ 5 5.2 Lubricating systems general ........................................................................................... 5 5.2.1 Splash lubrication .................................................................................................... 6 5.2.2 Forced lubrication systems ...................................................................................... 7 5.2.3 Combined lubrication systems................................................................................. 7 5.3 Cleanliness ...................................................................................................................... 7 5.3.1 Rinsing of lubrication system .................................................................................. 7 5.3.2 Recommended cleanliness of lubricant ................................................................... 8 5.4 Components .................................................................................................................... 8 5.4.1 Pumps ...................................................................................................................... 8 5.4.2 Filters ....................................................................................................................... 8 5.4.3 Cooler systems......................................................................................................... 9 5.4.4 Oil heaters................................................................................................................ 9 5.4.5 Tubes, hoses and fittings.......................................................................................... 9 5.4.6 Lubricant reservoir................................................................................................... 9 5.5 Additive systems........................................................................................................... 10 5.6 Lubrication analyses general......................................................................................... 10 5.6.1 Sampling techniques.............................................................................................. 10 5.6.2 Sampling from the gearbox ................................................................................... 11 5.6.3 Sampling from oil drums ....................................................................................... 11 5.6.4 On site testing.......................................................................................................... 11 5.6.5 Appearance test...................................................................................................... 11 5.6.6 Odour test .............................................................................................................. 11 5.6.7 Laboratory analysis ................................................................................................. 11 5.6.8 Recommended analysis limits ............................................................................... 11 5.6.9 Recommended properties of new oil ..................................................................... 11 5.6.10 Recommended analysis limits during operation .................................................... 12 5.7 Symbols for section 5. incl. annex C ............................................................................ 14 5.8 References for section 5. incl. annex C......................................................................... 15 6. Monitoring and maintenance ............................................................................................ 16 7. Tests and quality assurance .............................................................................................. 16 Annexes:

A B C D

Determination of gear loads (see section 2) Calculation of bearings (see section 3) Lubrication (see present section) Quality assurance (see section 7)

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Introduction
This recommendation is a supplement to the Technical Criteria for Type Approval and Certification of Wind Turbines in Denmark and is to be used for evaluation of gear boxes in that context. The recommendation has been prepared by a technical committee, set up by the Advisory Board for Approval of Wind Turbines in Denmark, under the auspices of the Danish Energy Agency. The recommendation is based on existing codes and standards for gear boxes supplemented by best engineering practice and state of the art knowledge from experts who have been consulted in the process. It should be kept in mind that the rules and recommendations reflect present knowledge and as such cannot cover all conceivable configurations of gearboxes to wind turbines. Compliance with this recommendation does not exempt the manufacturer from product liability. The Danish Energy Agency and the authors of the recommendation cannot in any way be held responsible for possible gearbox failures that might be connected with the content or the application of the present document. Please note: The present document is confined to section 5, Lubrication. See table of contents for reference to other items. Members of the Committee: Christer Eriksson John Steffensen Klaus rsted Petersen Ole Gunneskov Jens Demtrder Peter Schmidt Strange Skriver Flemming Vagn Jensen Sren Vestergaard Torben Kenneth Hansen Nils E. Werner Jens E. Fisker Egon T. D. Bjerregaard Poul Hjholdt Det Norske Veritas, Danmark A/S Vestas Wind Systems A/S Bonus Energy A/S NEG Micon A/S -do-doDanish Wind Turbine Owners Association SEAS Wind Energy Centre Tech-wise A/S -doCodan JFM Consult Ris, DEA secretariat Ris (Editor)

Preliminary drafts of the recommendation has been submitted for review by an international hearing panel.

Acknowledgement
The members of the Committee are acknowledged for the big effort they have put into the creation of the recommendation during laborious meetings, and the individuals in the hearing panel who have reviewed the draft versions are acknowledged for their written comments. The AGMA Wind Turbine Committee has kindly permitted that extracts from its draft material be used in the recommendation.

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1. Objective
The objective of this recommendation is to provide data and information that can be used in connection with the approval of gearboxes for wind turbines under the Danish Approval Scheme. The recommendation covers design loads, construction and manufacturing, maintenance and monitoring, testing and quality assurance in accordance with the scope of "Technical Criteria for the Danish Approval Scheme for Wind Turbines". Operation, service and maintenance of the gearbox are dealt with to the extent that such recommendations are important for the lifetime and safety of the wind turbine.

2. Climate, operating conditions and loads

See separate document.

3. Housing and bearings

See separate document.

4. Gear wheels and shafts

See separate document.

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5.0 Lubrication
Proper selection and condition monitoring of the lubricant is a profound issue to achieve unproblematic operation during the service life of a wind turbine. Of that reason the selection of the lubricant shall be the joint responsibility of the gearbox purchaser, the gearbox manufacturer, and other involved parties such as the lubricant supplier, bearing supplier or filter supplier. The wind turbine gears are characterised of relatively low pitch line velocity and high and alternating loads, which calls for oil with contents of extreme pressure additives (EP additive). As all components in the gearbox and lubrication system are affected by the lubricant, the effect on each component such as paints, seals, pumps, coolers, hoses etc. should be considered carefully. Minimum physical and performance specifications are provided in tables 5.2 and 5.3.

5.1 Lubrication regimes

Development and operational influence of the elastohydrodynamic (EHD) oil film depends on lubricant characteristics, lubricant inlet conditions, load intensity, operating velocity, surface conditions, metallurgy and cleanliness. It is common practice to categorise EHD lubrication into three regimes. 5.1.1 Full hydrodynamic conditions Full hydrodynamic lubrication exists when the lubricant film facilitates complete separation of the metal surfaces. Full EHD film is formed generally under conditions of light loads and moderate velocities or higher load intensities with higher velocities. Full EHD film is formed when the surface roughness asperities do not make contact with the opposite surface through the oil film. For surfaces manufactured on the basis of normal cutting operations like turning or grinding the roughness tops are so sharp that they retain their form until they break through the oil film and touch the opposite surface. The oil film thickness can thus be compared with the composite roughness of the two surfaces to determine the state of lubrication, the -value. For very smooth surfaces, and when surfaces have been run-in, the roughness tops are so smooth and blunt that they can work like small bearings and be elastically smoothened further until the wear stops. If the load or speed then is changed, the running-in starts again. The running-in process thus requires running at different loads and speeds to smoothen the asperity tops across the whole load-carrying surface. The lower film thickness used during the running-in, the smoother the surfaces will be. Mixed film conditions Mixed film lubrication exists where the surfaces operate with partial metal to metal contact. Mixed film lubrication is the most prevalent form and is generally associated with moderate velocities and relatively high load intensities. Boundary film conditions Boundary lubrication exists where the surfaces are wetted with oil but the film thickness developed is small compared to the surface roughness. Generally boundary lubrication is associated with low velocities and/or heavy load intensities. The lubricating system has to be considered as an integrated part of the gearbox from the very beginning of the design phase, and kept in eye through the entire development. The system shall always reflect the actual wind turbine concept and operating philosophy.

5.1.2

5.1.3

5.2 Lubricating systems general

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Proper function of the lubricant system shall be demonstrated under all relevant operational conditions. The function of the system may be demonstrated by tests in the workshop and/or by field tests on a prototype wind turbine. See section 7. The gearbox manufacturer and lubricant supplier shall be accurately informed of the operational conditions for the wind turbine. See section 2. The lubricating system shall always be equipped with an adequate filtering system to obtain the assumed cleanliness of the lubricant. At long lasting stand still in braked condition direct metal-to-metal contact will occur and may cause fretting corrosion. Consequently it is preferable to minimise the amount of time where the turbine is parked. Conditions during transportation and storing e.g. vibrations and corrosion have to be considered. For double row bearings the oil should be supplied in the middle of the bearing and drained to both sides. Oil level in the bearings shall not exceed half the diameter of the roller. Hot oil leaving from a gear mesh and ejected directly into the bearing shall be avoided. The actual operation philosophy has to be taken into account especially concerning lack of lubricant caused by variable speed or during idling and parking. In design and fabrication of the lubrication system the following subjects shall be considered: 5.2.1 proper supply of lubricant to each single lubricant point. pipes and other components should be designed on the large side to minimise viscosity dependence. proper workmanship has to be ensured. maintain adequate cleanliness during assembling, mounting and maintenance. proper installation of components with respect to vibrations, adequate function and damage during maintenance. it shall be possible to drain the gearbox and the entire lubrication system only leaving a negligible amount of lubricant left in the system. need for bleeding devices shall be considered

Splash lubrication Splash lubrication is a simple and reliable system and has done well in carefully designed and operated wind turbines. Especially for medium loaded helical gearboxes with relatively large oil volume. The low speed gear should dip into the oil bath for at least two times the tooth dept. Precautions has to be taken to capture the oil splash and conduct a proper amount to all bearings and meshes which are not immersed in the oil bath. Plates, scrapers and troughs have to be fastened and secured carefully. Precautions have to be taken to remove contaminates to achieve proper lubricant cleanliness.

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5.2.2

Forced lubrication systems These systems have the advantage to supply every bearing and gear mesh with the proper amount of lubricant at the temperature and cleanliness assumed in the design. It is recommended that all bearings and gear meshes, which are not immersed, are forced lubricated i.e. HSS and IMS bearings and HS gear mesh. The pressure level in the oil distribution system and pressure drop at the orifices shall be selected as low as possible to avoid unnecessary air intrusions. The system may be equipped with a cooler and shall be equipped with an adequate filter. Oil circulation has to be monitored continuously. Oil starvation during start up at cold conditions caused by high viscosity has to be considered. All internal tubes and spray nozzles should be accessible for tightening and control. Combined lubrication systems Combined lubrication systems act like splash lubrication at low oil temperatures and high oil viscosity. When the oil viscosity decreases at higher oil temperatures, a circulation system takes over and distributes the oil directly to gears or bearings. Oil filters and heat exchangers or oil coolers may be integrated in this system. Such systems allow for smaller sizes of pumps and oil lines; since they are not dimensioned for low viscosity and risk of cavitation is lower. The reduced filtration time achieved with such system shall be considered when determining the achievable cleanliness, unless a secondary filtration circuit is installed and permanently active.

5.2.3

5.3 Cleanliness
Proper cleanliness of lubricant is essential for trouble free operation of gears and bearings. This applies for mounting, run in and tests, as well as normal operation. 5.3.1 Rinsing of lubrication system All components in the gearbox including the lubrication system have to be cleaned separately before assembly, se also section 3. The cleanliness of the new lubricant has to be at least -/14/11 after ISO 4406. After pouring new lubricant in the gearbox and before applying loads, the gear has to be rotated at low speed to circulate the lubricant in order to rinse the gearbox and lubrication system. Loads shall not be applied before the cleanliness is at least /14/11. During run in and tests the cleanliness of the lubricant has to be monitored regularly and kept at a cleanliness of at least -/15/12. The oil sample should be taken through a test nipple before the filter (upstream). After run in and tests the components have to be carefully sealed before dispatch.

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5.3.2

Recommended cleanliness of lubricant Following values (partly DS 2395) for lubricant in sump may apply: Min. cleanliness of new lubricant whenever poured into the gearbox Min. cleanliness before applying load Min. cleanliness during run in and tests (at stabilised conditions) Min. cleanliness at scheduled maintenance but not longer than 3 months for the first sample and the following at fixed intervals typical 6 months Min. cleanliness immediate after commissioning or repair of gearbox/lubrication system Action programme 1. See table 5.3 Action programme 2. See table 5.3
-/14/11 -/14/11

Workshop conditions

-/15/12

-/16/13

1) Field conditions

-/16/13

/17/14 /18/15

1) Field condition means that an oil sample is taken and subsequent analysed.

Table 5.1 Recommended cleanliness of lubricants In this context the cleanliness used in bearing calculations should not be taken better than -/17/14. However if it can be demonstrated that the cleanliness always is better than -/17/14, a better cleanliness class may be used in the bearing calculations. In this case the cleanliness class chosen for the calculations shall be 1 class poorer than the documented cleanliness class. In that context the required cleanliness for all activities in table 5.1 has to be modified correspondingly.

5.4 Components
5.4.1 Pumps The pump may be driven by a gear shaft or an electric motor. The viscosity interval for proper operation of the pump has to be considered. Effects from cavitation and false air intake have to be evaluated. Filters Design of filters has to be considered carefully. At least the following subjects has to be considered: Flow capacity Filter capacity Mesh size and material Filtration rate x [ISO 16889] By pass valve with monitor

5.4.2

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The filter ratio x is defined as the number of particles at a size x m upstream divided with the number of particles down stream. The system design shall ensure that vibration, pressure spikes, bypass operation or other unforeseen events do not release particles already trapped in the filter. The filtration system, monitoring devices and associated service concept shall ensure that no harmful particles are released into the oil distribution system and that the oil in the sump remains on the cleanliness level assumed in the calculations even if the main filter is in bypass mode. 5.4.3 Cooler systems The cooler shall have sufficient capacity to keep the lubricant temperature at or below the design temperature. Oil heaters At low temperatures and high lubricant viscosity it can be necessary to heat the lubricant before start up to avoid oil starvation. The heating element surface temperature has not to exceed a temperature, which can be harmful for the lubricant. Tubes, hoses and fittings The hoses should be carefully chosen with respect to lubricant, pressure, flexibility and sturdiness. For lines subjected to pressure or suction, fittings and ports should have either high quality fittings or o-ring seals. The fittings should not be sensible to vibrations. Tubes and fitting made by copper or brass may cause electrolytic corrosion and should be carefully considered. Lubricant reservoir The lubricant reservoir may be either the gear housing itself or a separate tank. A suitable lubricant capacity may be calculated according to the following equation: Qr = PnomVspec Where Pnom the rated power in kW and Vspec is the specific lubricant volume in litre/kW. A specific lubricant volume not lower than 0.15 l/kW is recommended. For splash lubricated gearboxes without additional cooling a specific lubricant volume not lower than 0.4 l/kW is recommended. This is to ensure sufficient time to achieve proper separating of air bobbles and precipitate particles and water. The inlet- and outlet pipe shall be separated as much as possible e.g. by means of a separating baffle. To increase separating of air an inclined wire-gauze can be situated near the return tube. The meshes should be 25-50 m. The tank has to be equipped with a breathing filter with sufficient capacity to avoid pressure build up and with at least the same fineness as the system filter. The minimum lubricant level should be continuously monitored (e.g. by means of a minimum level switch) to avoid a leak in the lubrication system to cause gear failure.

5.4.4

5.4.5

5.4.6

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5.5 Additive systems

All commercial gear lubricants contain additives that enable them to meet specific performance requirements. Typical additives are: rust inhibitor oxidation inhibitor defoamant additive antiwear additive antiscuffing additive

Mineral and synthetic lubricants that contain special additives to prevent scuffing under boundary lubrication conditions are referred to as extreme pressure (EP) lubricants. Antiscuffing additives contain sulphur, phosphorus or other soluble compounds that form protective films to prevent scuffing. Be aware that a certain additive package is developed with a specific purpose e.g. protecting against scuffing and wear and as such probably only tested with respect to this specific purpose. It is recommended to investigate the properties of the lubricant with respect to all technical details, which are present in a wind turbine gearbox e.g. fatigue life of rolling bearings.

5.6 Lubrication analyses general

Sufficient informations concerning sampling of lubricant and the required analyses has to be stated in the service manual and the owners manual. 5.6.1 Sampling techniques Whenever samples are taken, it is important that the same procedures are followed so that consistent samples are obtained. Once the monitoring program has begun, do not change sampling procedures or sampling points without very strong reasons. Always use clean, plastic or glass sample bottles and keep all sampling equipment absolutely clean. Prior to sampling, fill out the label completely and attach it to the sample bottle. Be sure to record the wind turbine serial no., date and sample point. Oil sampling ports on splash lubricated gearboxes should be situated at a height corresponding to the middle of the operating oil level. If the oil sump is divided, there should be a port in both sections. Forced lubricated gearboxes should be equipped with two ports, one between the pump and the filter and one after the filter. To avoid misleading results causing hasty provisions at least the following subjects have to be considered: Samples have to be taken during operation at normal temperature. The oil sampling methodology, and analysing laboratory should not be changed without heavy reasons. Methodology may be according to ISO 4021. It is important to use absolutely clean fluid sample bottles and not to contaminate the samples during sampling. Cleaning of bottles may be according to ISO 3722. It is recommended to make plots of the result for each turbine to make the tendency in the contamination more clear.

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5.6.2

Sampling from the gearbox The surroundings and the sampling port have to be thoroughly cleaned before opening the port. Use a clean plastic hose and discard it after the sampling. Discard any oil in the drain valve including 3 times the dead volume in the tube in a separate bottle and obtain the sample to be analysed in a fresh bottle. Sampling from oil drums In terms of samples from near the top, the middle and near the bottom of the drum, a representative sample should be kept and stratification avoided. The sampling tube has not to touch the bottom and the side of the drum. To ensure this a sampling rod with a sampling tube tied to the three positions would be useful. In each point 1/3 of the sample are taken. On site testing Immediately after the sampling some simple investigations can be carried out: Appearance test Look at the lubricant in a clean narrow glass bottle. Compare the sample with a sample of new, unused lubricant. The oil should look clear and bright. If the sample looks hazy and cloudy, or has a milky appearance, there may be water present. A darkened colour may indicate oxidation or contamination with fine wear particles. Tilt the bottles and observe whether the used oil appears more or less viscous than the new oil. A change in viscosity may indicate oxidation or contamination. Look for sediment in the bottom of the bottle. Odour test Carefully sniff the oil sample, and compare the smell of the used oil sample with the new oil. The used oil should smell the same as new oil, that is should have a bland oily odour. Oils that have oxidised have a burnt odour, or smell acrid, sour or pungent. Laboratory analysis For monitoring the lubricant conditions during operation and for failure analyses a number of laboratory analysis are available. The most common are described in annex C. Also scale numbers for particle counting and characteristics of contamination particles can be found in annex C. Recommended analysis limits Immediately after the first start up, an oil sample should be taken and analysed, to state the point of reference. It should be born in mind that e.g. the tolerance on viscosity is 10% for new oil, and the TAN number varies a great deal from one oil type to another. Recommended properties of new oil The properties of new oil should comply with DIN 51 517 teil 3. and the following additional requirements will apply:

5.6.3

5.6.4 5.6.5

5.6.6

5.6.7

5.6.8

5.6.9

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Parameter Viscosity (mm2/s) Viscosity indices Oxidation stability Corrosion properties, Iron Corrosion properties, Copper Foaming properties Load carrying property (scuffing) Micropitting resistance test Filterability Cleanliness

Methodology ISO 3104 ISO 2909 ASTM D 2893 ISO 7120 (DIN51 355) ISO 2160 (DIN 51759) ASTM 892

Requirement 10% Min. 90 Increase in viscosity of a test sample oxidised at 121 C should not exceed 6% of reference value. No rust after 24 hours with synthetic sea water. #1b strip after 3 hours at 100 C Sequence 1: max. 75/10 10:00 Sequence 2: max. 75/10 10:00 Sequence 3 max. 75/10 10:00 Load stage min. 12 Stage 10 As stated in standard -/14/11

ISO 14 635-1 FVA, No 54 ISO/DIS 13 3571,2 ISO 4406

Table 5.2 Recommended additional properties of new lubricants Concerning the properties of the oil as specific lubricant in rolling bearing it has been shown that some additives may have a detrimental effect on the fatigue life of rolling bearings [5.23 5.25]. At present there exists no international or national recognised methodology dealing with lifetime testing of rolling bearings, but only internal praxis at the rolling bearing manufactures. However many bibliographies have been dealing with the subject. From these some information and practical advices may be deduced. A simple qualitative test can be carried out as static accelerated immersion test e.g. where bearing balls or rollers are kept immersed in the lubricant at a elevated temperature (160 C) for a certain time and compared with balls in a reference mineral base lubricant. The balls or rollers may show remarkable differences in colour and surface structure. When analysing the surface in microscope the corrosive effects of the additive film compared to that of mineral oil can be judged. If considerable changes are observed it is recommended to require additional documentation concerning the subject from the lubricant supplier. 5.6.10 Recommended analysis limits during operation To ensure trouble free operation it is essential to focus on at least the following issues: - control of viscosity - control of contents of contamination (water and particles) - control of contents of additives Figures in table 5.3 may apply:

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Analyse parameter

Normal

Changes in viscosity from point of reference Contaminants - Water contents 1) (mg/kg) - Changes in TAN (mgKOH/g) - Cleanliness (ISO 4406) - Wear particles/contaminants - Iron (mg/kg) - Copper (mg/kg) - Silicon 3) (mg/kg) Additives 2) - Contents of EP/AWadditives Oxidation stability 2) - Changes in TAN (mgKOH/g)

Within 10% < 200 0,5 -/15/12

Action programme 1. Intensified monitoring. New analyse Interval between 10% and 15% < 500 < 1,0 -/17/14

Action programme 2. Lubricant has to be cleaned or changed Outside 15% > 500 > 1,0 -/18/15

< 30 < 10 < 10 > 50 %

< 50 < 20 < 20 > 40 %

> 50 > 20 > 20 < 30 %

< 0,5

< 1,0

> 1,0

Table 5.3 Recommended properties of lubricants in operation

1): Borderline only valid for mineral lubricants and synthetic lubricants type PAO. 2): It is recommended to use the IR-spectrum to measure oxidation products in the lubricant and consumption of additives. 3): If Si compounds are used as anti foam additive, the figures may not apply.

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5.7 Symbols for section 5. incl. annex C

Pnom Nominal power Qr Lubricant reservoir volume Rq Root-mean-square deviation of the surface Vspec Specific lubricant volume hmin Minimum oil fil thickness x Separation ratio for filters at particles seize x m Specific oil film thickness ratio = hmin /(Rq1+ Rq2)1/2 [kW] [l] [m] [l/kW] [m] [-] [-]

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5.8 References for section 5, including annex C

[5.1] [5.2] [5.3] [5.4] [5.5] [5.6] [5.7] [5.8] [5.9] [5.10] [5.11] [5.12] [5.13] [5.14] [5.15] [5.16] [5.17] [5.18] [5.19] [5.20] [5.21] [5.22] [5.23] [5.24] [5.25] [5.26] [5.27] [5.28] [5.29] [5.30] DIN 4406 Method for coding level of contamination by solid particles DIN 51519 ISO-Viskosittsklassifikation fr flssige Industrie-Schmierstoffe ISO 11171 Hydraulic fluid power Calibration of automatic particle counters for liquids DS 2395 Skibs- og marineteknologi, Smreoliesystemer Vejledende rensningsgrader og flushing. DS 2397, Skibs- og marineteknologi Hydrauliksystemer Vejledende retningslinier for montage og flushing. DS 2398 Skibs- og marineteknologi Prveudtagning fra smreolie- og hydraulik rrsystemer. Vejledende retningslinier for udtagning af reprsentative vskeprver for renhedskontrol og partikkeltlling. DIN 51517-3 Schmierstoffe; Schmierle CLP; Mindestanforderungen. ANSI/AGMA 9005-D94 Industrial Gear Lubrication. ISO 16889 Hydraulic fluid power Filters Multi-pass method for evaluating filtration performance of a filter element. AGMA/AWEA 6006-AXX (Preliminary draft March. 2001) ISO 3448 Industrial liquid lubricants ISO viscosity classification ISO 3722 Cleaning of oil sample bottles. ISO 4021 Extraction of fluid samples from lines of an operating system. ISO 7120 Determination of rust-preventing characteristics in presence of water. DS Skibs- og marineteknologi Smreolierrsystemer Vejledende rensningsgrader og flushing. ISO 2160 Petroleum Products Corrosiveness to copper- copper strip test. ISO 2909 Petroleum Products Calculation of viscosity index from kinematic viscosity ISO 3016 Petroleum Products Determination of pour point DS/EN/ISO Olieprodukter Bestemmelse af kinematisk viskositet og beregning af dynamisk viskositet ISO/DIS 13357-1,2 Petroleum Products Determination of the filterability of lubricating oils ASTM D892-98, Standard test method for foaming characteristics of lubrication oils ASTM D 2893-99, Standard test method for oxidation characteristics of extreme pressure lubrication oils. H. P. Nixon: Effects of extreme pressure additives in lubrication on bearing fatigue life. G.T.Y. Wan, E.V. Amerongen and H Lankamp: Effects of extremepressure additives on fatigue life of rolling bearings. Harvey P. Nixon, Harry Zantopulos: Lubricant Additives, Friend or Foe. Klaus Michaelis: Gear Failures Definitions, Influence Factors, Rating Methods, Examples ISO 14635-1 Zhnrder FZG-Testverfahren Teil 1: Testverfahren A/8,3/90 fr relative Fresstragfhigkeit von len. FVA-Informationsblatt Nr. 54/I-IV DIN 51 354 Teil 1. FZG-Zahnrad-Verspannungs-Prfmaschine DIN 51 354 Teil 2. FZG-Zahnrad-Verspannungs-Prfmaschine. Prfverfahren A/3,8/90 fr Schmierle

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6. 7.

Monitoring and maintenance

See separate document.

Tests and quality assurance

See separate document.

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Annex C Lubrication (informative)

The contents in this annex C is based on the text in AGMA/AWEA 6006-AXX annex G, working draft. C1 C 1.1 Laboratory analysis Viscosity In the standard test, the time is measured for a fixed volume of liquid to flow under gravity through the capillary of a calibrated viscometer under a reproducible driving head and at a known and closely controlled temperature. The kinematic viscosity is the product of the measured flow time and the calibration constant of the viscometer. DS/EN ISO 3104 will apply. From the viscosity measured at two temperatures, normally 40 and 100, the viscosity index can be calculated. ISO 2909 will apply. The viscosity index characterizes the variation of the viscosity of a petroleum product with the temperature. In the wind turbine context a high index is desirable because it indicates a relatively small change of viscosity of the lubricant with the temperature, i.e. good starting properties and still sufficient lubricating capability at high temperature. An increase in viscosity for a mineral or PAO of a lubricant over that of fresh oil can be caused by oxidation or by contamination by dirt or water. A decrease in viscosity is unusual, but it can be caused by contamination with a solvent or a lower viscosity fluid. For ester lubricants a decrease in viscosity is normally related to a degradation of the lubricant by hydrolysis. The lubricant viscosity increases exponentially with increasing pressure. That increase is necessary for gear and rolling bearing lubrication. Normal lubricating oils have pressure viscosity coefficients in the interval 10-8 to 410-8 1/Pa, and the oil film thickness is proportional to the square root of the pressure viscosity coefficient. Water gives an extremely thin film build-up due top its low pressure-viscosity coefficient.

C 1.2 Total acid number The standard test for total acid number (TAN) is ISO/AWI 6619. The test uses potassium hydroxide (KOH) to neutralise the acid constituents in the lubricant. It yields a single number that represents the amount of KOH used for a given sample of lubricant in units of milligrams of KOH per gram of lubricant. When tested, most new, unused lubricants will have an acid number because the KOH reacts with the additives in the lubricant. Depending on the additive package, the new lubricant baseline TAN can vary widely. Therefore new lubricant should be tested to establish a baseline TAN. The TAN is a measure of the acidity of an oil sample. The higher the TAN, the more acidic constituents are present. The acids usually form when high temperature causes the oil to oxidize. The oxidation may be promoted by contaminants such as water, or debris such as iron and copper, that acts as catalysts. Oxidation is detrimental because it may increase the viscosity, cause residues and sludge, and create acids that promote corrosion. C 1.3 Water content Elevated water contents in the lubricant will cause reduced service life of both lubrication and components in the gearbox. The following effects are observed with elevated levels of water in the lubricant.

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Degrades the lubricant: - precipitates additives - promotes foaming - promotes oxidation - impairs lubricant film Degrades non-metallic components: - causes seal hardening - causes paint peeling - causes some plastics to swell or shrink Causes corrosion: - combines with sulphur to form sulphuric acid - causes rust particles that lead to abrasive wear and act as oxidation catalyst Promotes metal fatigue: - rust etch pits may initiate fatigue cracks - causes hydrogen embrittlement that promotes propagation of fatigue cracks Only the Karl Fischer titration method (ASTM D1744) possesses the necessary accuracy and sensibility. In some lubricant types with high contents of additives these additives may react with the Karl Fischer reagent and cause a false result. In that case the water has to be removed before the analysis. C 1.4 Spectrochemical analysis This test detects microscopic particles in an oil sample. The typical spectrometer is capable of identifying about 20 metals, the source of which may be wear debris, contaminants or inorganic additives in the lubricant. Knowing the type and quantity of metals can help diagnosing wear problems or disclose sources of contamination. Spectrochemical analyses are rapid and inexpensive. The oil sample is burnt and the light emitted is separated by diffraction into distinct wavelengths. Because each metal has its own characteristic wavelength, specific metals in the oil sample can be identified.

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Element Aluminium Antimony Arsenic Barium Bismuth Boron Cadmium Calcium Chromium Copper Indium Iron Lead Magnesium Manganese Molybdenum Nickel Phosphorous Potassium Silicon Sodium Tin Titanium Vanadium Zinc

Symbol Al Sb As Ba Bi B Cd Ca Cr Cu In Fe Pb Mg Mn Mo Ni P K Si Na Sn Ti V Zn

Typical source Dirt, labyrinth seal Bearings, grease Bearings Water, grease Bearings, additives Additives Bearings, plating Additives, water, grease, dirt Gears, shafts Cages bearings Solder Gears, shafts, rust, water Bearing, grease, paint, additives Dirt, additives Gears, shafts Gears, shafts, additives Gears, shafts Additives Dirt Additives, dirt, sealants Additives, dirt, grease Bearings, solder, coolers Paint, dirt Additives

Table C-1 Inorganic material in lubricant Emission spectroscopy works well for detecting metal particles up to 5-10 m. It will not detect particles greater than about 10 m, because it is incapable of completely and consistently burning larger particles. Therefore it readily detects particles from mild wear, polishing and micropitting because wear debris from these wear modes are within the detectable range. However failure modes such as severe abrasion, macropitting or scuffing usually generates particles that are larger than 10 m. In such cases, ferrography, particle counting or analysis with the Wear Particle Analyser may be superior monitoring techniques. Spectroscopy does not distinguish between particles of free metal and particles of metal oxides or other compounds of metal. For example rust particles may show up as increased iron content, but spectroscopy cannot identify whether the iron is in form of wear debris, iron oxide, iron sulphide, or rust. High contents of silicon or aluminium may indicate contaminants such as sand, dust or dirt. However there are other sources for silicon such as silicone antifoam additives or silicone gasket sealants. It is therefore important to analyse samples of fresh oil from new oil drums to establish a baseline level of silicon to help distinguish between contaminants and lubricant additives. It is helpful to plot the results of spectrochemical analyses over time. The graphs will indicate the normal test variability and will help one to follow any trends in test results. An accelerating wear problem is most easily predicted from a trend line that is increasing.

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C 1.5

Automatic particle counting Particle counters monitor the number of particles of a given size range in a given lubricant sample. A common method for determination of lubricant cleanliness, detects all particles regardless of their composition and is capable of detecting particles in the range of 4- 100m. Particle counters are either of the light-interruption type or the laser scanning type. Either method provides analyses that are rapid and inexpensive. Light-interruption particle counters flow the lubricant through a small passage while a light beam scans the oil through a window. Particles in the lubricant that are within a set size range momentarily interrupt the light beam. The output from a detector that senses the interruption of the light beam is related to the time of interruption and hence the size of the particle. Laser-scanning particle counters operate on a principle that is similar to that of the light-interruption type, except the oil sample remains stationary in a clear glass container while it is scanned by a revolving laser beam. The range of the particle size is selectable, i.e. as it is the case with the light-interruption method. Limitations of automatic particle counting: While particle counting detects all particles, it gives no information on the shape or the composition of the particles. It is susceptible to incorrect counts caused by mistakenly counting bubbles of air or water. For accurate results, the oil sample should be well agitated to produce a uniform suspension of particulates, and the concentration of particles should be low enough to avoid counting two or more particles as one. ISO solid contamination code The ISO Solid Contamination code, ISO 4406 1999 is used. The difference between the 1999 edition and the 1987 edition is that the new introduces a three part code for levels measured with automatic particles counters calibrated in accordance with ISO 11 171. The particle sizes to be reported for measurements by using a microscope, 5m and 15m are unchanged from those specified in ISO 4406:1987. The code for contamination levels using automatic particle counters comprises three scale numbers, which permit the differentiation of the dimension and the distribution of the particles as follows: the fist scale number represents the number of particles equal to or larger than 4m per millilitre of fluid. the second scale number represents the number of particles equal to or larger than 6m per millilitre of fluid. the third scale number represents the number of particles equal to or larger than 14m per millilitre of fluid

C 1.6

The code for microscope counting comprises two scale numbers using 5m and15m.

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Number of particles per millilitre More than Up to and including 2 500 000 2 500 000 1 300 000 1 300 000 640 000 640 000 320 000 320 000 160 000 160 000 80 000 80 000 40 000 40 000 20 000 20 000 10 000 10 000 5 000 5 000 2 500 2 500 1 300 1 300 640 640 320 320 160 160 80 80 40 40 20 20 10 10 5 5 2.5 2,5 1.3

Scale number >28 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8

Table C-2 Allocation of scale numbers ISO 4406 C 1.7 Ferro graphic analysis Ferro graphic analysis separates wear debris and contaminants from a lubricant sample by magnetic precipitation. It is capable of precipitating particles that range from less than 1m to greater than 200 m. Ferrography provides two types of analysis, a relatively inexpensive direct-reading (DR) Ferro graph, and a more expensive analytic Ferro graph. In the DR Ferro graph, a diluted sample of the lubricant is siphoned through a precipitation tube that resides in a powerful magnetic field. The combination of magnetic force and the viscous forces exerted by the lubricant causes the particles to be separated according to size. The larger particles (>5m) are deposited first, near the entry of the tube then the smaller particles (1-2m) deposit father down the tube. Two light beams pass through the precipitation tube, one at the entry deposit and one several mm farther down the tube where small particles deposit. Light attenuation at the two locations along the tube is used to quantify the relative amount of large to small particles. The results are reported as two scalar readings, direct large (DL) and direct small (DS). In the analytical Ferro graph, a diluted sample of the lubricant is pumped across a microscope slide that is mounted at an angle above a magnet so that the field varies along the length of the slide. The particles are subjected to a continuously increasing magnetic force as they flow along the slide. Consequently the particles precipitate distributed according to size, along a narrow band about 50mm long. Ferrous particles line up in strings that follow the magnetic lines. Nonferrous particles and contaminants travel down the field in a random pattern. The slide is washed with a fixative that washes away the oil, locks the particles in place, and floats away other material. The Ferro gram (slide upon which particles have been deposited) is examined in a bichromatic microscope equipped with a camera. The microscope uses both transmitted green light projected from the bottom of the Ferro gram and red light reflected from the top of the Ferro gram to distinguish the size, shape, texture and

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composition of both metallic and non-metallic particles. The particles have characteristics that help determine the wear mechanism and identify the sources of the particles. C 1.8 Characteristics of particles Wear particles Rubbing Sliding Cutting Fatigue Laminar Spherical
Flat platelets < 15 thick < 1 mm long. Found in lubricants of all machines, and are indicators of normal wear. Generally >15 with length/thickness ratio between 5 and 30. Surfaces have parallel striations and may have temper colours. That is evident of severe sliding. Long, curled chips resembling lathe cuttings. They are evidence of abrasive wear. May be caused by contamination of lubricant by hard sharp-edged particles. Generally > 5 with length/thickness ratio < 5. Surfaces are rough and particles are shaped like chunks of coal, rather than platelets. Thin, bright particles often with holes in their surfaces and edges that are split. Length/thickness ratio > 30. Typical of gear and rollingbearing wear particles that pass between contacting surfaces. Generally < 15 diameter with smooth surfaces. They are a precursor to rolling- bearing fatigue failure.

Table C-3 Wear particles

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Ferrous oxides Red oxide Dark metal oxide Black oxide Corrosion
Red/orange particles magnetically aligned. Appear thick, rounded and translucent. they are severe sliding wear particles that have oxidised. Resemble red oxide sliding wear particles, except they are not translucent. Often show flecks of free metal on their surfaces. They are caused by heat and may be evidence of lubricant starvation or severe wear. Dark grey/black particles magnetically aligned. Shaped like pebbles. They are evidence of inadequate lubrication and represent a more severe condition than red oxide particles. Fine deposit of < 1 size particles at the exit of ferrogram. They are formed by corrosive attack of metal surfaces and depletion of lubricant additives

Table C-4 Ferrous oxides Contaminants Friction polymer Sand/Dirt Fibres Spheres Other
Amorphous, translucent material of no particular size. Indicates lubricant polymerisation under extreme conditions. Generally > 5 crystalline particles, not magnetically aligned. Translucent, fibrous particles not magnetically aligned. Typical fibres include hair, cotton, wood, glass, minerals, nylon and cellulose. Generally > 5 with rough surfaces. May be contaminants from grinding, welding or shot blasting. Contaminants such as paper, paint, varnish, glue, gasket or seal material, or lubricant additives such as molybdenum disulfide or graphite.

Table C-5 Contaminants C 1.9 Wear particle analyser In the wear particle analyser, a diluted sample of lubricant is drawn through a filter that is in a strong magnetic field. The filter has a matrix of fine ferromagnetic fibres that become magnetized in the magnetic field. The fibres capture particles magnetically, and physically capture particles larger than the spacing between the fibres. A flux sensor determines the changes in the magnetic field due to presence of particles, and displays the magnetic equivalent of the captured particles in micrograms of iron metal. The reading known as the magnetic iron content (MIC) is independent of particle size. The wear particle analyser is capable of capturing particles of 1m and larger with a efficiency of 95% or greater. The filter can be back washed with solvent to recover the particles for microscopic examination and other diagnostic analyses.

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