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Making renewable energy greener with oil analysis and contamination control


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Webinar Description:
Renewable Energy is important for many reasons. To remain viable as an alternative energy source these technologies must run reliably and at the lowest possible cost. Lubricated machines such as turbines and gearboxes require proper oil care and management. In this informative webinar led by C.C. Jensen's Justin Stover, you will learn practical steps that will make Renewable Energy greener; by conserving precious resources and slashing O&M costs.

Instructor: Justin Stover, C.C. Jensen, Inc.
Justin Stover earned his degree in 2001 in fluid power technology. He has more than 10 years experience in helping end users and OEM's in the Wind industry implement, develop and deploy contamination control programs. He is certified by the International Council for Machinery Lubrication as a Level 1 Machinery Lubricant Analyst.

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Making renewable energy greener with oil analysis and contamination control

  1. 1. Making Renewable Energy GREENER with Oil Analysis and Contamination Control I. The Importance of Analysis and Filtration II. Case Studies III. Questions and Answers
  2. 2. The Importance of Analysis and Filtration Renewable Energy is Important to C.C.JENSEN Our Wind Turbine covers 40 % of our energy consumption
  3. 3. The Importance of Analysis and Filtration Renewable Energy is Important for Many Reasons… it’s Clean, Available, and Provides Security.
  4. 4. The Importance of Analysis and Filtration WIND TURBINES – Pushing the Design Envelope 2 million N-m (1,475,000 lb-ft) Extreme pressure on components BLADES 120 m (394 ft)
  5. 5. The Importance of Analysis and Filtration CLEAN OIL GEARBOX PITCH HYDRAULIC Extreme pressure BLADES 120 m (394 ft) on components MAIN BEARING GETS MORE AND MORE IMPORTANT
  6. 6. The Importance of Analysis and Filtration THE IMPORTANCE OF CLEAN OIL AND IT’S IMPACT ON RELIABILITY HAS BEEN KNOWN FOR DECADES “Replacing 40-25µm filters by units rated at 3µm absolute is to be recommended for gearboxes. Such action should lead to improved reliability, longer periods between overhaul, cheaper overhauls, and consequent reductions in ownership costs. Times between oil changes, where relevant, should be substantially increased.” 1979 The Influence of Filtration on Rolling Element Bearing Life Source: R. Bhachu, R. Sayles, and P.B. Macpherson
  7. 7. The Importance of Analysis and Filtration Did You Know? The estimated gearbox failure in a Wind Turbine is estimated at $250,000! Ref: NORIA
  8. 8. The Importance of Analysis and Filtration “Bearings Don’t Fail… They’re Murdered” Ref: NORIA
  9. 9. The Importance of Analysis and Filtration Did You Know? The estimated cost of an oil change is $5,000 on a Wind Turbine. LESS USE OF FOSSIL OIL LESS TRANSPORTATION LESS WASTE OIL IMPROVED FILTRATION IS ABLE TO KEEP THE OIL CLEAN AND MAKE IT LAST LONGER
  10. 10. The Importance of Analysis and Filtration Every Barrel Counts… 16,000 Wind Turbines X 100 Gallons = 29,090 Barrels Three-Year or Six-Year Oil Service Life – Which is GREENER?
  11. 11. The Importance of Analysis and Filtration Oil Analysis Reduces Maintenance and Downtime! PARTICLES WATER OXIDATION
  12. 12. The Importance of Analysis and Filtration End of Section I Take Away: No machine has ever failed because the oil was too clean; What get’s measured get’s done. Question: What is the most important parameter on your oil analysis test slate?
  13. 13. Case Study – Hydro Power
  14. 14. Case Study – Hydro Power “We sampled using the procedure and the iso(c) code came back as 13/11/8. That’s the cleanest our oil has been in years!”
  15. 15. Case Study – Hydro Power Used Filter Ideal for Filter Debris Analysis
  16. 16. Case Study – Hydro Power Filter Debris Analysis
  17. 17. Case Study – Wind Power “The oil at [our project] is the exact opposite of the [clean] oil, its beyond filthy!! We should have taken out disaster insurance on it…you would not believe or want to see what comes out of one of these when you turn it upside down. Well, maybe you would. It was the most disgusting, revolting lumpy stinky slime I’ve ever seen come from the bowels of the gearbox.”
  18. 18. Case Study – Wind Power
  19. 19. Case Study – Wind Power Filter Debris Analysis
  20. 20. Case Study – Wind Power
  21. 21. Case Study – Wind Power
  22. 22. Case Study – Wind Power 591500 PROBLEM •After 2 years using O.E.M 10-micron in-line filter – particle count + 500,000 4-micron 230000 particles per/100 ml. ISO 20/18/15 Date 129200 42800 “Since [upgrading our filtration] our oil analysis has showed considerable improvement, and our gearbox has yet to have a single bearing failure, vibration analysis alarm, or high-heat signature. We are likely to save major repairs – that may cost over $900,000” 50300 SOLUTION 16600 174003800 1200 incl. air bleed HDU 15/25 PV2-7-4 1x120V, 60hz hose > 4 micron > 6 micron > 14 micron Filter Insert: BG 15/25, 3 μm absolute filtration Pump flow: 57 L/h 01/24/2011 11-07-2010 02/25/2011 11/07/2010 01/24/2011 02/25/2011 > 4 micron 591,500 129,200 42,800 > 6 micron 230,000 50,300 16,600 > 14 micron 17,400 3,800 1,200 ISO Code 20/18/15 17/16/12 16/15/11
  23. 23. Case Study – Solar Power
  24. 24. Case Study – Solar Power
  25. 25. Case Study – Solar Power
  26. 26. Case Studies End of Section II Take Away: Identify oil problems and take action to correct; Monitor the oil to ensure progress is made. Question: What type of contamination do you most often see?
  27. 27. Q&A Questions & Answers
  28. 28. THANK YOU! For more information please contact: Justin Stover C.C. Jensen, Inc. 206-390-5438