Wind Turbine Grease Sampling and

Analysis
Richard N. Wurzbach
ASNT Level III PdM
Machinery Lubricant Analyst, Level II
MRG Labs
York, Pennsylvania
Lubricant Sampling
• Oil analysis using valves and gravity
• Drop tube sampling
• Retrofit sampling mini-mess
• Importance of sample location
• Drop tube point of
sample uncertain

Image from Noria Corporation

Grease Sampling
• Historically during disassembly following failure
• Using “popsicle stick”, screwdriver, cable ties
• Samples only available near access points, ports
• “Grab Sample” has similar limitations to “Drop
Tube Sampling”
• ASTM Grease subcommittee initiates working
group to develop sampling standard, 2009
• Projects initiated in USA and Denmark to test
effectiveness of grease sampling in 2010, 2012
Motor Operated Valves (MOV)
• EPRI method using
plastic tubing at gears
• Grease removed and
visually inspected
• Kits made utilizing
known consistency Photos: Bolt, et. al. Machinery Lubrication Magazine. May 2003

greases for comparison

to obtained sample
• Questionable samples;
very subjective analysis
Grease sampling devices
• Maintain purge function with little/no backpressure
when threaded into machine
• Can be attached to T-handle for precise sample location
adjacent to internal gears
• Design to optimize the analysis process
Sampling Techniques
• MOV Gearbox
1 2 3 4 5

• Electric Motor Bearing

1 2 3 4 5

• Pillow Block Bearing

1 2 3 4
MOV Test Stand-EPRI Project

Actuators filled with in-service grease

Cycled forward and backward
Produced video of grease flow
Data on consistency of wear levels
Wear monitoring
• Hall effect sensor counts total ferrous debris
level of sample, not the variable amount
through the body of grease

Standard Relative Standard

Method Average
Deviation Deviation
fdM+ 277 ppm 7 2.53
DR- 205 46 22.44
RDE 57 ppm 16 28.07
Wear Evaluation
Wind Turbine Lubricant Monitoring

10
Wind Turbine grease sampling and analysis
• 2-year project conducted with DONG Energy and
Vattenfall, two largest offshore wind operators in the
world
• Dr. Kim Esbensen, internationally recognized expert in
Theory of Sampling (TOS), Denmark
• Rich Wurzbach, MRG Labs, inventor of Grease Thief
• Systematic evaluation of grease heterogeneity, sampling
methodology, and analysis validity and repeatability for
wind turbine main bearings in on-shore and off-shore
applications
• Results published at OilDoc, LUBMAT, and AWEA
Wind Main Bearing Sampling
• Grease flow dependent on
temperature, bearing
movement
• Grease Thief & T-handle
used to capture flowing
grease
• Revised T-handle developed
for Denmark Off-shore Wind
Research Project

12
ASTM Standard Development
• Incorporation of grease sampling research
• Inclusion of historical methods for sampling
with considerations and limitations
• Failed component sampling, care in obtaining
sample or multiple samples
• Use of tubing, adequacy of suction alone,
possibility of peripheral grease sampling
• Inclusion of new technologies for active and
passive sampling
Active Sampling
• T-handle Coring with active
or passive sampler
• Spatula and syringe on
pillow block
• Syringe and tubine on
slewing bearing

“Taking a sample” from Rothe Erde “Grease Sampling Set” instructions

Cautions and Concerns
• Use of plastic tubing may not properly suction
all representative grease, point of sampling may
vary, as in oil “drop-tube” sampling
• Samples must be taken from “live-zone” in the
machine, understanding of flow dynamics
important
• Sample must be properly labeled and protected
during shipment
• Quantity must be sufficient for required tests
Acceptance and Use
• D7718 is basis for AWEA Recommended Practices for
wind turbine sampling
– 812 Grease Sampling - Main Bearing
– 813 Grease Sampling - Generator Bearing
– 814 Grease Sampling - Pitch Bearing
– 815 Grease Analysis
• Used by largest operators in Danish Offshore Wind industry
• Published by US Nuclear Industry in “Effective Grease
Practices” NMAC Guideline
• Analysis utilized by labs in Europe, Asia, North America
• Sampling kits used on six continents around the globe
Analysis Techniques

Sample is received. fdM+ is run Die extrusion is performed and substrate is made

Two strips are used to make One Strip is used One Strip is Dissolved in Green
a dilution to run RDE/ICP. for FT-IR. RULER solution to run RULER.
17
Die Extrusion Analyzer
Grease Consistency – Back Bearings in a USA
Wind Farm: Outliers in Yellow
 Optical Spectroscopy

• Optical spectroscopy quantifies the appearance of grease

• Grease aging, contaminants, mixtures, chemometrics
20
FdM Wear Levels across Wind Farm

21
3-D Sampling, OEM repair shop
3-D sampling
Trends of moisture in bearings

900

800

700 Grease type: SKF LGWM1

• Thickener: Li
600
• Base oil: Mineral oil
• Viscosity @ 40C: 200 cSt
Moisture, ppm

500 314 Front • NLGI-class: 1

314 Rear
400
319 Front
319 Rear
300

200

100

0
3 3 3 3 3 3 3
/20 9/3/201 7/2/201 /31/201 5/1/201 /11/201 /26/201
1
10/8 5 4 2
Next Steps
• Development of ASTM Standard for Grease Analysis
– Integrated Tester section of ASTM with a balloted Work Item
– Currently in Interlaboratory Study (ILS) in US labs for precision
statement
– Laboratories in Asia, Europe and North America to participate in
development of methods
• Development of “Slim” version of sampler to access rail
locomotive wheel bearings, certain wind bearings
• Mini-lab development for “In-Sampler” Analysis, including
ferrous debris, colorimetry
• Real-time particle counting in grease as it is being extruded
• Major lubricant manufacturers worldwide utilizing for support
of customer base