Wind Power Solutions Internormen Product Line. Lubrication Systems, Filter Systems, and Accessories for Wind Power Gears

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1 Wind Power Solutions Internormen Product Line Lubrication Systems, Filter Systems, and Accessories for Wind Power Gears

2 Eaton combines sales, engineering, manufacturing, customer service, and technical sales support into one focused business objective: Provide customers with optimum filtration solutions. Eaton s Filtration business is a leader in manufacturing filtration products and solutions that include measurement, diagnostic and analysis technology. Following a path of continuous improvement, Eaton has maintained quality as a fundamental corporate strategy and a hallmark of all products and services. Eaton s Internormen Product Line currently includes more than 4,000 hydraulic filter elements and corresponding filter housings. Hydraulic Filtration Product Families: Hydraulic & Lubrication Systems Hydraulic & Lubrication Filters Condition Monitoring Hydraulic Filter Accessories Hydraulic System Cleanliness Cleanliness is the measure of solid and liquid contamination found in hydraulic systems. Contamination is defined as any substance not part of a hydraulic system s working fluid. Eaton Filtration Services State-of-the-art testing lab facilities Equipment rentals Field service inspections, field trials, start-up, repair, replacement, and maintenance Extensive network of sales and service representatives Worldwide technical support Product specialists dedicated to providing application engineering The Importance of Cleanliness Provides maximum efficient productivity Improves control of spare parts through preventive maintenance and monitoring Reduces equipment downtime through scheduled inspections Minimizes safety hazards and prevents contaminationrelated failure Increases the life expectancy of system components, which both increases operating profitability and decreases maintenance costs Reduces repair costs and system downtime Eaton Sustainability Commitment Occurrence of Contamination There are three principal means where contamination can occur in a typical hydraulic system: Incorporated during system assembly Generated during system operation Ingested by the system during operation Eaton is unwavering in our commitment to being sustainable by design in the way we operate, through the design of our products, and through the energy and climate saving benefits our products deliver. Eaton issues a Sustainability Report as part of its Annual Report, available on

3 Lubrication Systems, Filter Systems, and Accessories for Wind Power Gears It is particularly important that wind turbine lubricants provide appropriate protection of gearboxes against corrosion, wear and tear. Most lubrication and hydraulic systems failures are caused by oil contamination. That is why proper oil maintenance, monitoring, and filtration are an essential part of preventive, structured maintenance programs. Wind power is not only the fastest growing energy production platform in the world, it is also one of the cleanest renewable power sources on Earth. As turbines are getting larger and offshore systems become more common, the possibility to build wind power plants almost anywhere makes their growth inevitable. Effective and consistent lubrication of components can sometimes be a challenge in wind turbines. Contaminants, like solid particles or moisture can enter the gearbox during manufacturing and assembly, or in the initial run-in process, or during routine maintenance. Contaminants also can be ingested through seals and breathers, or internally generated during regular operations. Proper oil maintenance, monitoring, and filtration are essential parts of preventive, structured maintenance programs. Experts recommend equipping wind power systems with: Additional filtration systems Metal particle monitoring systems Solid contamination monitoring systems Water-in-oil monitoring systems Water removal systems High quality desiccant breathers Heating systems for cold environments Cooling systems Lubrication System Diagram Twinfil Filter Systems MPS Metal Particle Sensor Legend p1: Pressure filter ON p2: Pressure filter OFF p4: Pressure hose ON p5: Bypass ON p6: Pressure cooler ON p7: Pressure cooler OFF p8: Pressure flow junction TB: Temperature casing T1: Temperature filter ON T6: Temperature cooler ON T7: Temperature cooler OFF VM: Flow measuring device K: Cooler Q: Oil flow pump Q1: Oil main flow filter Q2: Oil parallel flow filter Q3: Oil flow to the gear Q5: Deaeration flow QK: Oil flow cooler QB: Oil flow bypass E1: Permanent deaeration VD1: Valve with filter element 51 psi (3.5 bar) VD2: Valve to cooler 7.3 psi (0.5 bar) VD3: Valve to bypass 87 to 174 psi (6 to 12 bar)

4 Twinfil Filter Systems Features Specially designed gear lubrication systems Reliably supplies all gear lubrication points as it filters and deaerates the system Low noise emission Indicates oil operating condition Prolongs lubricant service life Simple to service Operates in cold weather conditions with an additional pump-assisted heating system Available Options Condition Monitoring Systems Metal particle sensors (MPS) Water sensors (WSPS) Multifunction oil condition sensors (IVS 01) Clogging Indicators Electric, electronic, or visual pressure differential indicators to monitor filter operating conditions. They may be connected to the filter without any tubes. Twinfil Filter System Water Removal Filter Elements Use for particle retention and absorption of free and emulsified water from oil Reduce oil aging and deadditivation of fluids Filter, Valve, and Cooling System Function from Cold Start to Normal Operating Temperature Start Trial Results Tests under simulated cold start conditions down to -22 F (-30 C) operating and -40 F (-40 C) survival temperatures and with a special gear oil yielded the following results: Oil flow through the air-oil cooler could be attained after two minutes The adjustable pressure differential valve (VD3) appeared to influence how long it took to see a temperature increase (T7) at the cooler outlet. Based on the oil flow (QK 20% of the total flow Q), and at pressures from 87 to 174 psi (6 to 12 bar), the times ranged from 10 to 2 minutes All system components worked properly from cold start up to maximum temperature. Whenever measured, oil viscosities were < 4635 SUS (1000 mm²/s), and the oil flow was 100% filtered through the main element (filter fineness 10 µm, fiber glass fleece) Performance Tests Eaton s Internormen product specialists coordinated with customers and other partners to test the TWF system s functionality. They simulated cold start conditions (down to -22 F (-30 C) operating and -40 F (-40 C) survival temperatures) and used special gear oils. They found that all system components including the pump, filter, valves, and tube system worked properly from cold start to the 158 F (70 C) maximum operating temperature without any negative effect on the overall gear-oil supply. T7 F ( C) 59 (15) 50 (10) 41 (5) 32 (0) 23 (-5) 14 (-10) 5(-15) -4 (-20) Trial Start 1 VD3 174 psi (12 bar) Δ pk min = 55 psi (3.8 bar) OK > 4 gal/min (15 l/min) 2 10 Trial Start 2 VD3 87 psi (6 bar) Δ pk min = 55 psi (3.8 bar) OK > 4 gal/min (15 l/min) [min]

5 Twinfil Filter Systems TWF 1001 with MPS TWF 1001 Flow rate: E-motor - rotary current: E-motor - protection class: IP psi (16 bar) maximum 31.7 gal/min (120 l/min) -22 F (-30 C) minimum -40 F (-40 C) minimum 400/690 V, 50 Hz/60 Hz TWF 1950 Flow rate: E-motor - rotary current: E-motor - protection class: IP psi (16 bar) maximum 52.8 gal/min (200 l/min) -22 F (-30 C) minimum -40 F (-40 C) minimum 400/690 V, 50 Hz/60 Hz TWF 1950 TWF 6000 TWF 4000 TWF 4000 Flow rate: E-motor - rotary current: E-motor - protection classes: IP psi (16 bar) maximum 66 gal/min (250 l/min) -22 F (-30 C) minimum -40 F (-40 C) minimum 400/690 V, 50 Hz/60 Hz TWF 6000 Flow rate: E-motor - rotary current: E-motor - protection classes: IP psi (16 bar) maximum gal/min (400 l/min) -22 F (-30 C) minimum -40 F (-40 C) minimum 400/690 V, 50 Hz/60 Hz

6 CSM 02 CSM 02 - Contamination Sensor Monitor Applications In-line particle counting in the wind turbine gearbox oil can quickly present the following challenges: High viscosity oils and variations in outdoor temperatures can significantly affect measurement systems Foamed oils make particle counting in wind power plants additionally difficult WGR 60 - Maintenance Unit Inexpensive maintenance unit meant for quick, clean change of filter element without oil loss Oil is pumped out of the filter housing into an appropriate reservoir and pumped back into the system after the filter has been changed Especially suitable for application in wind power plants : Dimensions: Weight: 20.5 x 14 x 28.7 in (520 x 355 x 730 mm) 26.5 lb (12 kg) Barrel capacity: gal (60 l) Flow rates: Viscosity: Suction/pressure hose: 59 in (1.5 m) Connection: Power supply: 1.3 to 4 gal/min (5 to 15 l/min) 18,540 SUS (4000 mm²/s) G 1 / 2 threaded 230 V TWF 1950 with WGR 60 Features Use as a stationary or mobile oil condition monitoring system Operates off-line, independent of the system being measured Analyzes the amount and size of solid contamination in hydraulic and lubrication fluids Easily upgraded with additional sensor modules to measure other important fluid parameters Measures foamed oils accurately Effective for early detection of changes in fluid cleanliness and oil composition as well as contamination increases Useful for quality control, maintenance, and during initial operations Software updatable through SD card Remote control via Internet or Intranet Graphic display of stored measurements Storage capacity 8 x 100 measurement results English and German languages available : Voltage supply: 230 V, 50 Hz / 110 V, 60 Hz Pressure operating range: -2.9 to 2.9 psi (-0.4 to 0.5 bar) Viscosity: 92.7 to 4635 SUS (20 to 1000 mm 2 /s) Max. oil temperature: 32 to 158 F (0 to 70 C) Ambient temperature: 32 to 122 F (0 to 50 C) Protection class: IP 54 Output signals: Two alarm signals; limit values programmable RS232 / RS485 output, USB, Ethernet Alarm through via Internet Measurement results displayed on monitor Printing function with optional thermal printer Operation: On touch-screen Measuring Parameters: Particle counting: Contamination classes - acc. to ISO 4406:99 Water saturation: 0 to 100% Temperature: 32 to 158 F (0 to 70 C) Dynamic viscosity: 9 to 900 mpas Relative dielectric constant: 1 to 10 Weight: 72.8 lbs (33 kg) approximately

7 Retrofit Filter Systems US 10 US 22 with Metal Particle Sensor US 22 The US 22 stationary filter units are intended for oil maintenance in hydraulic systems, applications include: Secondary flow filtration in addition to an existing operating filter Secondary flow filtration without an operating filter Filtration when filling the oil reservoir The US 22 unit should not be used to pump contaminated hydraulic fluids and is therefore designed without a switch-over fitting to by-pass the filter. Features like high reliability and small dimensions are guaranteed by its compact structural design on a base plate without a pipe. The device is equipped with a gear pump driven by an E-motor. Easy to replace filter elements are available in different fineness. : Filter fineness: Weight: 4.5 μm(c), 7 μm(c), or 10 μm(c) 77.1 lbs (35 kg) (approx.) Operating medium: Hydraulic oil based on mineral oil from 46.4 SUS (10 mm²/s). Other media on request. Metal Particle Sensors Additionally, the US 22 can be equipped with an MPS - Metal Particle Sensor having the following features: Detection of metal particles Designed as an inexpensive in-line monitoring solution for stationary and permanent operations Suitable for installation in new or existing systems Operating with inductive measuring concept for hydraulic and lubricating fluids Various types: MPS 01.2, MPS 02.1, MPS 03.1 US 10 The US 10 stationary filter units are designed for servicing oil at gears with lubricants of high viscosity. The units perform off-line filtration, and are constructed on a base plate without a tube, which guarantees small dimensions and high reliability. The stationary filter unit can operate unattended. The electric security and switch elements of the filter unit perform the following functions: Motor protective switch turns E-motor off when overloaded Thermostat switches on the pump depending on the respective gear temperature Pressure switch (clogging indication E5.5) acts as protection against permanent overload (> 72.5 psi, 5 bar) Time lag relay bridges the cold start of E5.5 The conduction, deaeration, and diversion connections are marked US 10 with Control Unit corresponding to their function. Diversion is necessary for the purification of the filter unit and appropriate replacement of the filter element as well as for changing the fluid to be filtered. : Flow rate: E-motor: Power supply: Max. Pressure: Filter fineness: Weight: Medium : 3 gpm (11.3 l/min) at 700 rpm 0.37 KW, about 700 rpm 230/400 V, 50 Hz 116 psi (8 bar) 5 μm(c), 7 μm(c), 10 μm(c), 15 μm(c), or 20 μm(c) 77.1 lbs (35 kg) (approx.) Hydraulic oil based on mineral oil, 46.4 to 13,905 SUS (10 to 3000 mm²/s)

8 Wind Energy in Cold Climates Take advantage of wind power even in the coldest regions of the world. Cold climate and severe outdoor conditions have particularly undesirable effects on wind turbines, primarily affecting plastic and steel components and lubricants. At low temperatures, the viscosity of lubricants and hydraulic oils increases, causing the oil to stiffen, leaving it unable to sufficiently lubricate the gearbox and bearings. If the oil is too thick to freely circulate, damage to the gears will occur almost immediately. An increase in internal friction will reduce the power transmission capacity of the gearbox. It is also important to account for servicing and monitoring the system under difficult cold weather conditions. Increased maintenance costs and extended turbine downtime need to be considered. To significantly improve the dependability and extend the service life of wind turbines under cold, unpredictable winter conditions, Eaton offers a variety of Internormen product solutions. Twinfil Filter Systems with Additional Pumpassisted Heating System Pump heating: E-motor: psi (15 bar) maximum -22 F (-30 C) minimum -40 F (-40 C) minimum 4 x 100 W, 230 V Customer-specific HSH Oil Pre-heater for Suction Hoses Heating elements Features Suction hose heater placed inside the Eaton Internormen DN 60 suction hose Additional 59 (1.5 m) heater connection line and inlet Excellent cold start performance of the gear pump Benefits High power (350 W/m) ensures exceptionally quick heat-up time: from -22 to 40 F (-30 to +5 C) in 20 minutes Overheat control prevents oil combustion Outer sheath, made of stainless steel wave tube, is leak-proof and compatible with different media Temperature control at the surface of the stainless steel wave tube (up to a maximum of 140 F (60 C)) Hose to heater is sealed without compression glands Various hose lengths available (standard: 59 (1.5 m)) Tube length: 59 (1.5 m) (other lengths available on request) Connections: 2 x SAE 2 (other connections available on request) Nominal diameter: DN 60 Power supply: 230 V~ (other supply voltages available on request) Power: 350 W/m -22 F (-30 C) minimum -40 F (-40 C) minimum

9 HS Heating Systems Features Provides quick additional gear oil heating when extremely low temperature conditions push oil viscosity up to 741,6000 SUS (160,000 cst (mm²/s)) Two types available - HS 10 and HS 16 - each operates at 116 or 174 psi (8 or 12 bars) maximum pressure Fitted for survival temperatures from -40 to 176 F (-40 to 80 C) Systems are maintenance-free and equipped with a monitoring device to prevent oil overheating H3 H2 H1 HS 10 HS or 174 psi (8 or 12 bar) maximum 116 or 174 psi (8 or 12 bar) (maximum) Operating fluid: Poly-alpha-olefin or mineral oil-based gear oils Operating fluid: Poly-alpha-olefin or mineral oil-based gear oils Starting viscosity: 741,600 SUS (160,000 mm²/s) maximum Starting viscosity: 741,600 SUS (160,000 mm²/s) maximum -22 F (-30 C) minimum, 86 F (30 C) maximum -22 F (-30 C) minimum, 86 F (30 C) maximum -40 F (-40 C) minimum, 176 F (80 C) maximum -40 F (-40 C) minimum, 176 F (80 C) maximum Operating voltage: 400/460 V ΔAC (other voltages upon request) Operating voltage: 400/460 V ΔAC (other voltages upon request) Frequency: 50/60 Hz Frequency: 50/60 Hz Hydraulic thermal output: 1000 W (maximum) Hydraulic thermal output: 1500 W (maximum) Electric thermal output: H1: 2 x 100 W, 230 V AC H2: 2 x 160 W, 230 V AC H3: 3 x 2500 W, 400 V AC Electric thermal output: H1: 2 x 100 W, 400 V AC H2: 2 x 250 W, 400 V AC H3: 6 x 2500 W, 400 V AC Geared pump: 80 cm³/rev, gal/min (52 l/min) at 750 rpm, gal/min (62 l/min) at 500 rpm Geared pump: 80 cm³/rev, gal/min (52 l/min) at 750 rpm, gal/min (62 l/min) at 500 rpm Electric motor: 3.0 kw Electric motor: 3.0 kw

10 Lubrication Systems, Filter Systems, and Accessories for Wind Power Gears Filter Systems Contamination Monitoring Systems Heating and Cooling Systems Twinfil Lubrication and Filter Systems for Gears TWF 1001 TWF 1950 TWF 4000 TWF 6000 Filter Units Stationary US 10 US 22 with MPS 01.2 Lubrication Systems For Main Bearings of Wind Turbine Gears Supplementary Products WGR 60 maintenance unit for filter change Filter Elements Sensors Metal Particles MPS 01.2 MPS 02.1 MPS 03.1 Water Contamination WSPS Oil Condition IVS 01 In-line Measuring Systems Particle Counter CSM 02 MPM 01 - Set Water Contamination WSTM 01 - Set Oil Condition IVS 01 On-line/Off-line Measuring Systems Multi-analysis Systems OCM 01 Water Contamination WSH 01 Heating Systems HS 10 HS 16 HSH - Heated Suction Hose

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12 North America HQ 70 Wood Ave., South, 2nd Floor Iselin, NJ Toll Free: (800) (North America Only) Voice: (732) China No. 3, Lane 280, Linhong Road Changning District, Shanghai, P.R. China Voice: Singapore 4 Loyang Lane #04-01/02 Singapore Voice: Europe/Africa/Middle East Auf der Heide Nettersheim, Germany Voice: Internormen Product Line Friedensstraße 41 D Altlussheim, Germany Voice: Begerow Product Line An den Nahewiesen Langenlonsheim, Germany Voice: Brazil Av. Julia Gaioli, 474 Bonsucesso Guarulhos, Brazil Voice: +55 (11) For more information, please us at filtrationinfo@eaton.com Visit us online at eaton.com/filtration for a complete list of Eaton s filtration products 2012 Eaton Corporation. All Rights Reserved. All trademarks and registered trademarks are the property of their respective owners. Litho USA. All information and recommendations appearing in this brochure concerning the use of products described herein are based on tests believed to be reliable. However, it is the user s responsibility to determine the suitability for his own use of such products. Since the actual use by others is beyond our control, no guarantee, expressed or implied, is made by Eaton as to the effects of such use or the results to be obtained. Eaton assumes no liability arising out of the use by others of such products. Nor is the information herein to be construed as absolutely complete, since additional information may be necessary or desirable when particular or exceptional conditions or circumstances exist or because of applicable laws or government regulations. EFINWPR 6-12