Design World

  • Home
  • Technologies
    • 3D CAD
    • Electronics • electrical
    • Fastening & Joining
    • Factory automation
    • Linear Motion
    • Motion Control
    • Test & Measurement
    • Sensors
    • Fluid power
  • Learn
    • Ebooks / Tech Tips
    • Engineering Week
    • Future of Design Engineering
    • MC² Motion Control Classrooms
    • Podcasts
    • Videos
    • Webinars
  • LEAP AWARDS
  • Leadership
    • 2022 Voting
    • 2021 Winners
  • Design Guide Library
  • Resources
    • 3D Cad Models
      • PARTsolutions
      • TraceParts
    • Digital Issues
      • Design World
      • EE World
    • Women in Engineering
  • Supplier Listings

How magnetic oil filtration helps gearboxes work longer

By Paul Dvorak | November 3, 2016

Share

Randy Yount / VP of Operations / FilterMag

randy_yount_-_suit

Randy Yount

According to the National Renewable Energy Lab (NREL), gearbox problems are the number one cause of turbine downtime. Although the wind industry is getting a handle on why gearboxes do not function for 20 years, it is still necessary to keep a close eye on them through condition-monitoring systems and regular oil analysis. The reason a gearbox needs close attention is the failure of bearings, especially on the high-speed shaft. Currently, most bearing failures eventually result in a gearbox change.

NREL also cites the average cost to change a high-speed shaft bearing up tower at about $46,000. What’s worse is the average cost to exchange the gearbox. It’s about $424,000.

A typical wind-turbine installation wraps a FilterMag XT8PR around a gearbox oil filter. A stainless-steel band secures the magnets to the aluminum filter housing. Captured particles are wiped from the inside wall of the housing during a filter change.

However, using magnetic filtration to capture the debris from a failing bearing, along with early detection, could save an operator more than $300,000 for a single bearing failure. And when gearboxes are installed in offshore wind turbines, as they will be in some 8-MW units, a long working gearbox life is all the more important.

It is generally accepted that when a failing bearing is detected soon enough and damage to the rest of the gearbox controlled, then it is possible to replace a bearing instead of having to change the gearbox. Condition monitoring with an early borescope evaluation can identify the bearing problem. The most damaging particles are less than 10 µm in size, small enough the pass through standard filtration. Magnetic filtration can mitigate the collateral damage to the rest of the gearbox by capturing the debris generated by a slowly failing bearing.

To test the magnetic capture of fine steel particles in gearbox oil, three 1.5­MW wind turbines monitored by gearbox­oil analysis were each fitted with a pair of magnetic filters on their existing filter housings. Hydac 5­µm filtration was used on each turbine. Oil sampling was conducted at 1, 2, and 4 months after the magnet installations.

Analysis of gearbox oil subjected to magnetic filtration with a conventional 5­µm filter revealed an overall 78% reduction in oil contamination, which leads to a calculated 50% longer bearing life and 30% longer gear life.

Analysis of gearbox oil subjected to magnetic filtration with a conventional 5­µm filter revealed an overall 78% reduction in oil contamination, which leads to a calculated 50% longer bearing life and 30% longer gear life.

The test demonstrated that a 78% reduction in total particles was possible after four months. Average ISO 4406 particle counts changed from 19/17/14 to 17/15/12. According to data from the Noria Corporation, this change of two code drops would indicate that bearings could last 50% longer and gears 30% longer. Noria is a Tulsa-based tribology consulting and training company.

Magnetic filters are available for most existing oil filters. The outside diameter of a spin-on oil filter or the outside diameter of a filter canister determines which unit fits a particular application. The magnetic traps also work on hydraulic systems.

A typical spin-on oil filter that had been fitted with a FilterMag has been dissected to show the steel particles captured and held in place by the magnets. The image on the right is a microscopic view of captured particles all smaller than 20 microns.

The magnetic filters are reusable and typically outlast the equipment on which they are installed. Other types of magnetic filtration are available but generally require plumbing equipment in-line.

Windpower Engineering & Development


Filed Under: Renewable energy, Gears • gearheads • speed reducers

 

Related Articles Read More >

Solar Atmospheres partners with energy storage company
Material simulation, testing improve lifespan of offshore wind turbines
TEGAM announces the ultimate handheld meter – the Display Probe
Harting presents new wind solutions at HUSUM Wind

DESIGN GUIDE LIBRARY

“motion

Enews Sign Up

Motion Control Classroom

Design World Digital Edition

cover

Browse the most current issue of Design World and back issues in an easy to use high quality format. Clip, share and download with the leading design engineering magazine today.

EDABoard the Forum for Electronics

Top global problem solving EE forum covering Microcontrollers, DSP, Networking, Analog and Digital Design, RF, Power Electronics, PCB Routing and much more

EDABoard: Forum for electronics

Sponsored Content

  • Global supply needs drive increased manufacturing footprint development
  • How to Increase Rotational Capacity for a Retaining Ring
  • Cordis high resolution electronic proportional pressure controls
  • WAGO’s custom designed interface wiring system making industrial applications easier
  • 10 Reasons to Specify Valve Manifolds
  • Case study: How a 3D-printed tool saved thousands of hours and dollars

Design World Podcasts

May 17, 2022
Another view on additive and the aerospace industry
See More >
Engineering Exchange

The Engineering Exchange is a global educational networking community for engineers.

Connect, share, and learn today »

Design World
  • Advertising
  • About us
  • Contact
  • Manage your Design World Subscription
  • Subscribe
  • Design World Digital Network
  • Engineering White Papers
  • LEAP AWARDS

Copyright © 2022 WTWH Media LLC. All Rights Reserved. The material on this site may not be reproduced, distributed, transmitted, cached or otherwise used, except with the prior written permission of WTWH Media
Privacy Policy | Advertising | About Us

Search Design World

  • Home
  • Technologies
    • 3D CAD
    • Electronics • electrical
    • Fastening & Joining
    • Factory automation
    • Linear Motion
    • Motion Control
    • Test & Measurement
    • Sensors
    • Fluid power
  • Learn
    • Ebooks / Tech Tips
    • Engineering Week
    • Future of Design Engineering
    • MC² Motion Control Classrooms
    • Podcasts
    • Videos
    • Webinars
  • LEAP AWARDS
  • Leadership
    • 2022 Voting
    • 2021 Winners
  • Design Guide Library
  • Resources
    • 3D Cad Models
      • PARTsolutions
      • TraceParts
    • Digital Issues
      • Design World
      • EE World
    • Women in Engineering
  • Supplier Listings