Wind turbine pitch hydraulic oil contamination reduced
Increased particle and water contamination was detected in the pitch hydraulic systems of Vestas V90-2MW wind turbines. After installing a refurbished CJC™ HDU 15/25 PV Fine Filter, particle levels were reduced by 95% and water content significantly lowered, improving oil cleanliness and extending hydraulic component lifetime.
Application Snapshot
Industry:
Wind
Country:
Sweden
Oil type:
Texaco Rando HDZ 32
Executive summary
Chongqing Gearbox required a documented flushing result of ISO code 17/15/12, but previous gear flushing equipment from both domestic and international suppliers could not reach this requirement. The outcome was very long flushing processes with high electricity consumption, without achieving the wanted cleanliness level.
Due to poor experiences in the market, Chongqing Gearbox was reluctant when C.C.JENSEN presented the CJC™ Gear Flushing Unit (GFU). A test on sale-on-return conditions was agreed, with the objective to reach and document ISO 17/15/12 in 3 hours. The flushing started at a contamination level of 3,000,000 particles per 100 ml (>4 micron) and was reduced to below 50,000 in less than 2 hours, achieving the objective faster than promised.
Significant particle reduction
2 µm particles in Pitch Hydraulic System #7 were reduced by 95%, from 34,631 to 1,539 particles per 100 ml within one month of filtration.
Improved ISO cleanliness
ISO cleanliness improved from 16/15/8 to 11/10/7 in System #7 and from 17/15/8 to 13/12/8 in System #12 after installation of the CJC™ HDU Fine Filter.
Water content reduced to stable level
Water content in System #7 decreased from 1,859 ppm to 86 ppm, while System #12 was reduced from 347 ppm to 82 ppm, improving overall oil condition.
Extended component lifetime
The reduced flushing time delivered an electrical cost saving equivalent to 160 USD per gearbox, with break-even in less than one year.
Measured oil condition development
After one month of operation with the CJC™ HDU Fine Filter, significant improvements were recorded. In Pitch Hydraulic System #7, 2 µm particles were reduced by 95%, from 34,631 to 1,539 particles per 100 ml. ISO cleanliness improved from 16/15/8 to 11/10/7, and water content decreased from 1,859 ppm to 86 ppm.
In Pitch Hydraulic System #12, ISO cleanliness improved from 17/15/8 to 13/12/8, while water content was reduced from 347 ppm to 82 ppm.
According to industry experience and Noria Corporation, this level of oil cleanliness can extend hydraulic component lifetime by a factor of more than 2.5.
Results and operational impact
The installation of the CJC™ Fine Filter significantly improved oil cleanliness in the pitch hydraulic systems. Particle contamination was reduced dramatically and water levels lowered to a fraction of the initial values.
Improved oil condition enhances wear protection and supports reliable turbine operation. Based on industry experience, the improved cleanliness can extend the lifetime of hydraulic components by more than 2.5 times.
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