FUCHS PETROLUB AG1

Understanding what makes Wind Different Wind Power Applications Application Requirements Windpower Oil Windpower Greases Summary

AGENDA:

FUCHS LUBRICANTS

3

Fuchs Lubricants is a $2 Billion Lubricants global manufacturer.

Fuchs has been in the Wind Business for almost 20 years.

Fuchs provides greases, oils and assosciated products to the Wind power industry.

Fuchs works closely with the OEM turbine manufacturers and the equipment manufacturers to provide premium products to the different and difficult Wind applications

4

U.S. Wind Power, by State & Region

As of Sept 30th there were approximately 49,000 operating wind turbines in the U.S.

Source: AWEA 2015 3rd Qtr Report

5

WIND POWER OPERATING CONDITIONS

300 Feet in the Air 6 Month Maintenance Cycle Intermittent and Variable Usage High Vibration Environment Extremely Large /Complicated / Expensive

Components Exposed to the Elements

What Makes Wind Different

WIND TURBINE – Working Principle

RotorBlades

Generator

Low speed shaft

Kinetic Energy

Mechanical Energy

Electrical Energy

High speed shaft

Wind Turbine Main Components and Lubrication Points

Yaw (Azimuth) bearing

Rotor bearing (Main bearing)

Generator bearing

Yaw drive

Pitch drive & Pitch bearing

Main gear

Generator bearings

Main bearings

Gear Box

Pitch/Yaw bearing

Yaw/Pitch Gear Teeth Flanks

Many Components

9

$50,000 Lubricant only costs for wind turbine maintenance. How much grease and oil is used?

Huge potential lubricant related failure costs..What does a main bearing cost you?

Over $300,000 to replace a Main Gearbox, including Crane Charges

Too much , too little , too early , too late all can cost the Wind Farm money. How do you decide when and how much?

COSTS OF LUBRICATION

Different Components >> Different Requirements

Each component has different types of contact

Each component has different requirements

Each component requires a specific lubricant

HOW DO YOU DECIDE WHICH LUBRICANT TO USE

10

Different Components >> Different Requirements

Main Gearbox OilLong Life ( desire 20 years, Ave = 5-7

years)High Costs of FailureLow Temp, High Speed, Moderate

LoadsComplex Gear and Bearing systemOil Changes are Expensive

11

12

GE 2.9 two-stage planetary and one-stage parallel shaft (bottom) wind turbine gearboxes (Image: GE).

MAIN GEARBOX

MAIN GEARBOX OIL REQUIREMENTS

13

Requirements and indicators for using

OIL in Wind Turbines

14

GEAR OIL DATA

December 2012 - PM415

FAG 4 Step Test Results : general overview

WIND OIL TESTING -- FAG

SKF Test Results Part 3 :

Excellent:

•Corrosion Protection NaCl – Emcor test

•Oxidation stability•FE8 wear protection•Low foaming•......

WIND OIL TESTING -- SKF

Flender Foam Test Results

Oil Volume, 1Litre Spur Gears Oil Temperature, 25°C 5 Minutes Run Volume of Foam and Oil-Air Dispersion < 15% Foam, 1Minute after Stopping

WIND OIL TESTING --- FLENDER

18

OIL FILTERABILTY

Test Fuchs Standard

MethodOther possible

Methods UnitFreshoil up to 4.000 h

or 6 month

24.000 hor 3 yrs Warning Limits

Appearance Visual Visual clear liquid precipitations

Color DIN ISO 2049 0 - 1,5 0 - 8 not applicable

Viscosity @ 40°C DIN EN ISO 3104 ASTM D 445 mm²/s 288 - 352 (typ.: 320) 270 - 405 < 270 or > 405

Viscosity @ 100°C DIN EN ISO 3104 DIN EN ISO 3104 mm²/s 29-39 ( typ.35 ) < 24 or > 45

Viscosity Index DIN ISO 2909 ... 135-161 < 130

Unresolved Material DIN EN 12662 DIN ISO 5884 % < 0.05 < 0,5 > 1

Ferrography IndexFLV-F-15 (Fuchs Lab-

method) PQ-Index Analizer ... < 20 < 100 > 100

Water content (Karl Fisher)

KF, indirectDIN 51777-2 DIN ISO 3733 mg/kg / ppm < 100 < 500 > 500

Density @ 15 °C DIN 51757 ASTM D 1298 kg / dm³ 0,850 - 0,8650,850 -

0,865 +/- > 15 %

Neutralization no. - TAN DIN 51558-1 ASTM D 664 or 974 mgKOH/g 0,4-0,7 (typ.: 0,6) < 2,0 > 2,0

TYPICAL OIL LIMITS

TYPICAL ELEMENT LEVEL FOR GEAR OIL

December 2012 - PM420

Used oil limits

Test / Prüfung Standards/ Methode Unit/Einheitfreshoil up to 4.000 h

or 6 month 24.000 h or ³3 yrs Warning Limits

Al content / Gehalt ICP (Plasma Spectrometer) mg/kg < 5 < 20 > 20

Fe content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 100 > 100

Zn * content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 50 > 50

Cu content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 50 > 50

Cr content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 20 > 20

Sn content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 20 > 20

Si content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 30 > 30

Mg * content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 50 > 50

Mo * content / Gehalt ICP (Plasma Spectrometer) mg/kg <5 < 100 > 100

P content / Gehalt RFA (DIN 51363-2) mg/kg 190 - 250 > 150 < 150 or > 275

S content / Gehalt RFA (DIN EN ISO 14596) mg/kg 3800 - 4800 > 3000 < 3000 or > 5200

Ca content /Gehalt RFA (DIN 51363-2) mg/kg typ. 22 13- 50 < 5 or > 50

Cleanliness class / Reinheitsklasse ISO 4406 17 / 14 / 11***

21

USED OIL ANALYSIS

GE 1.5 Turbine Winergy Gearbox

Attribute UnitComponent Gearbox Gearbox Gearbox Fresh oilOil

Measured Data :AO aminicaccording to Ruler

RAO[%] 75 97 63 -

phosphorus (RFA) mg/kg 359 343 337 236lead (ICP) mg/kg < 5 < 5 < 5 < 5iron (ICP) mg/kg 13 10 11 < 5zinc (ICP) mg/kg 190 180 170 < 5silicon (ICP) mg/kg < 5 < 5 < 5 < 5aluminium (ICP) mg/kg < 5 < 5 < 5 < 5copper (ICP) mg/kg < 5 < 5 < 5 < 5chromium (ICP) mg/kg < 5 < 5 < 5 < 5tin (ICP) mg/kg < 5 < 5 < 5 < 5magnesium (ICP) mg/kg 66 58 55 < 5nickel (ICP) mg/kg < 5 < 5 < 5 < 5molybdenum (ICP) mg/kg 64 49 50 < 5natrium (ICP) mg/kg 9 17 15 5calcium (ICP) mg/kg 13 13 12 19phosphorus (ICP) mg/kg 330 298 290 209barium (ICP) mg/kg < 5 < 5 < 5 < 5Viscosity@ 40C cst 332.5 327.8 326.5 320

TANmgKOH/g 0.72 0.75 0.77 0.4-0.7

Water Content PPM 24 76 72 < 100

Different Components >> Different Requirements

Yaw/Pitch Gearboxes and Hydraulic System Smaller , somewhat less critical applications Less lube usage

Yaw and Pitch Gear Teeth Flanks HIGH load Only a small % of the area used Vibration also an issue

Main Bearings Low Speed 23-30 RPM Fairly heavy loads Largest Grease user

22

23

Diagram courtesy of NREL

Nacelle weights 56Blade assembly weights 36 Tons

KEY COMPONENTS

Different Components >> Different Requirements

Generator BearingsHigh Speed 12-18,000 RPM Lightly loadedHigh temp operation a concern

Yaw and Pitch Bearings High shock loading Limited movement, pitch has many more small adjustments

Low temp can be an issue

OthersFastener Lubrication/ProtectionChain Hoists / LiftsBalance of Plant24

FUCHS PETROLUB AG25

LUBRICATION INTERVAL

.. In other words…

HOW MUCH?

HOW OFTEN?

WHEN TO CHANGE?

….easy questions with an “uneasy answer”….

26

LUBE INTERVAL AND VOLUME

What does the OEM say?

What does history tell you?

Are you using the proper lubricants?

Are you using auto lubricators?

Feed back from condition monitoring and oil/grease analysis?

27

Do you have a predictive maintenance system?

Has the environment been different?

What do your technicians see?

SUMMARY

The Wind Market represents a unique and diversified lubrication challenge

Lubrication is an integral part of the entire Economic Structure of the Wind Turbine

As the components evolve and change so do lubricants

Each application has unique requirements that call for specific performance from the lubricant

The cost of the lubricant itself is only a small part of the total costs associated with the entire lubrication process

28

THANKS FOR YOUR ATTENTION

29