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Monitoring of Wind Turbine Gearbox Condition through Oil and Wear Debris Analysis: A Full-Scale Testing Perspective
Despite the wind industry's dramatic development during the past decade, it is still challenged by premature turbine subsystem/component failures, especially for turbines rated above 1 MW. Because a crane is needed for each replacement, gearboxes have been a focal point for improvement in reliability and availability. Condition monitoring (CM) is a technique that can help improve these factors, leading to reduced turbine operation and maintenance costs and, subsequently, lower cost of energy for wind power. Although technical benefits of CM for the wind industry are normally recognized, there is a lack of published information on the advantages and limitations of each CM technique confirmed by objective data from full-scale tests. This article presents first-hand oil and wear debris analysis results obtained through tests that were based on full-scale wind turbine gearboxes rated at 750 kW. The tests were conducted at the 2.5-MW dynamometer test facility at the National Wind Technology Center at the National Renewable Energy Laboratory. The gearboxes were tested in three conditions: run-in, healthy, and damaged. The investigated CM techniques include real-time oil condition and wear debris monitoring, both inline and online sensors, and offline oil sample and wear debris analysis, both onsite and offsite laboratories. The reported results and observations help increase wind industry awareness of the benefits and limitations of oil and debris analysis technologies and highlight the challenges in these technologies and other tribological fields for the Society of Tribologists and Lubrication Engineers and other organizations to help address, leading to extended gearbox service life.
A Unit Laboratory Engine Oil System Providing for a Remote Indication of Oil Flow and Oil Consumption Together with Blow-by Measurement
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Investigation of 75-millimeter-bore cylindrical-roller bearings at high speeds III : lubrication and cooling studies - oil inlet distribution, oil inlet temperature, and generalized single-oil-jet cooling-correlation analysis
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Assessment of the Technical and Economic Potential to Produce Oil and Store CO2 by Applying CO2 Enhanced Oil Recovery to Greenfield Residual Oil Zones within the Permian Basin
Presented by NETL at Carbon Capture, Utilization and Storage Conference 2018, 03/18
How Much Oil and CO2? At What Cost? Bounding the Quantities of Produced Oil and Stored CO2 from CO2 EOR in Conventional Oil Fields in the United States
Presented by NETL at American Institute of Chemical Engineers, 10/18
Capacity assessment and co-optimization of CO 2 storage and enhanced oil recovery in residual oil zones
Residual oil zones (ROZs) are increasingly being commercially exploited using CO 2 -enhanced oil recovery (CO 2 -EOR) method. In this study, CO 2 storage potential, long-term CO 2 fate and oil recovery potential in ROZs are characterized based on a reservoir model for Goldsmith-Landreth San Andres Unit in the Permian Basin. The effects of CO 2 injection rates, well patterns (five-spot and line-drive), well spacings, injection modes (continuous CO 2 injection and water-alternatinggas injection) on the CO 2 retention in the reservoir and the oil production are investigated. After the preliminary assessment of CO 2 storage and EOR potentials in ROZs, we next develop a novel approach based on a newly developed optimization algorithm-Stochastic Simplex Approximate Gradient (StoSAG) and predictive empirical models constructed using machine learning technique to co-optimize CO 2 storage and oil recovery in ROZs. The performance of co-optimization of CO 2 storage and oil recovery is compared with the performance of optimization of only CO 2 storage.
Oil-impregnated densified wood veneer with high electrical insulation enabled by nanosized oil channels
Growing energy demands and renewable integration are stressing the aging power grid infrastructure. Lignocellulosic oil-impregnated paper is widely used in power transformers but suffers from critical limitations, such as low dielectric strength, mechanical strength, and thermal conductivity, causing premature transformer failures. Here, we demonstrate a superior electrically insulating oil-impregnated paper design using the naturally anisotropic structure of densified wood veneer to achieve nanosized channels of oil that efficiently disrupt electrical breakdown pathways. The developed oil-impregnated densified wood (ODW) creates aligned cellulose fibers with 166 ± 87–nanometer oil nanochannels, achieving record dielectric strength of 105 kilovolts per millimeter. The structure also delivers a mechanical strength of up to 384 megapascals and a thermal conductivity of 0.33 watts per meter per kelvin, enabling enhanced longevity upon thermal aging tests. The ODW could replace conventional transformer insulation to enhance power transformer performance and improve lifetime. Moreover, its anisotropic oil-filled nanochannel design offers a general strategy for hybrid dielectrics in medium- and high-voltage applications.
Corexit 9500 Enhances Oil Biodegradation and Changes Active Bacterial Community Structure of Oil-Enriched Microcosms
To better understand the impacts of Corexit 9500 on the structure and activity levels of hydrocarbon-degrading microbial communities, we analyzed next-generation 16S rRNA gene sequencing libraries of hydrocarbon enrichments grown at 5 and 25°C using both DNA and RNA extracts as the sequencing templates. Oil biodegradation patterns in both 5 and 25°C enrichments were consistent with those reported in the literature (i.e., aliphatics were degraded faster than aromatics). Slight increases in biodegradation were observed in the presence of Corexit at both temperatures. Differences in community structure were observed between treatment conditions in the DNA-based libraries. The 25°C consortia were dominated by Vibrio , Idiomarina , Marinobacter , Alcanivorax , and Thalassospira species, while the 5°C consortia were dominated by several species of the genera Flavobacterium , Alcanivorax , and Oleispira . Most of these genera have been linked to hydrocarbon degradation and have been observed after oil spills. Colwellia and Cycloclasticus , known aromatic degraders, were also found in these enrichments. The addition of Corexit did not have an effect on the active bacterial community structure of the 5°C consortia, while at 25°C, a decrease in the relative abundance of Marinobacter was observed. At 25°C, Thalassospira , Marinobacter , and Idiomarina were present at higher relative abundances in the RNA than DNA libraries, suggesting that they were active in degradation. Similarly, Oleispira was greatly stimulated by the addition of oil at 5°C While dispersants such as Corexit 9500 can be used to treat oil spills, there is still debate on the effectiveness on enhancing oil biodegradation and its potential toxic effect on oil-degrading microbial communities. The results of this study provide some insights on the microbial dynamics of hydrocarbon-degrading bacterial populations in the presence of Corexit 9500. Operational taxonomic unit (OTU) analyses indicated that several OTUs were inhibited by the addition of Corexit. Conversely, a number of OTUs were stimulated by the addition of the dispersant, many of which were identified as known hydrocarbon-degrading bacteria. The results highlight the value of using RNA-based methods to further understand the impact of dispersant on the overall activity of different hydrocarbon-degrading bacterial groups.
Data for Creating Yellow Seed Camelina sativa with Enhanced Oil Accumulation by CRISPR-Mediated Disruption of Transparent Testa 8
Camelina ( Camelina sativa L.), a hexaploid member of the Brassicaceae family, is an emerging oilseed crop being developed to meet the increasing demand for plant oils as biofuel feedstocks. In other Brassicas, high oil content can be associated with a yellow seed phenotype, which is unknown for camelina. We sought to create yellow seed camelina using CRISPR/Cas9 technology to disrupt its Transparent Testa 8 (TT8) transcription factor genes and to evaluate the resulting seed phenotype. We identified three TT8 genes, one in each of the three camelina subgenomes, and obtained independent CsTT8 lines containing frameshift edits. Disruption of TT8 caused seed coat colour to change from brown to yellow reflecting their reduced flavonoid accumulation of up to 44%, and the loss of a well-organized seed coat mucilage layer. Transcriptomic analysis of CsTT8-edited seeds revealed significantly increased expression of the lipid-related transcription factors LEC1, LEC2, FUS3, and WRI1 and their downstream fatty acid synthesis-related targets. These changes caused metabolic remodelling with increased fatty acid synthesis rates and corresponding increases in total fatty acid (TFA) accumulation from 32.4% to as high as 38.0% of seed weight, and TAG yield by more than 21% without significant changes in starch or protein levels compared to parental line. These data highlight the effectiveness of CRISPR in creating novel enhanced-oil germplasm in camelina. The resulting lines may directly contribute to future net-zero carbon energy production or be combined with other traits to produce desired lipid-derived bioproducts at high yields.
History Matching and Performance Prediction of a Polymer Flood Pilot in Heavy Oil Reservoir on Alaska North Slope
The first-ever polymer flood pilot to enhance heavy oil recovery on Alaska North Slope (ANS) is ongoing. After more than 2.5 years of polymer injection, significant benefit has been observed from the decrease in water cut from 65% to less than 15% in the project producers. The primary objective of this study is to develop a robust history-matched reservoir simulation model capable of predicting future polymer flood performance. In this work, the reservoir simulation model has been developed based on the geological model and available reservoir and fluid data. In particular, four high transmissibility strips were introduced to connect the injector-producer well pairs, simulating short-circuiting flow behavior that can be explained by viscous fingering and reproducing the water cut history. The strip transmissibilities were manually tuned to improve the history matching results during the waterflooding and polymer flooding periods, respectively. It has been found that higher strip transmissibilities match the sharp water cut increase very well in the waterflooding period. Then the strip transmissibilities need to be reduced with time to match the significant water cut reduction. The viscous fingering effect in the reservoir during waterflooding and the restoration of injection conformance during polymer flooding have been effectively represented. Based on the validated simulation model, numerical simulation tests have been conducted to investigate the oil recovery performance under different development strategies, with consideration for sensitivity to polymer parameter uncertainties. The oil recovery factor with polymer flooding can reach about 39% in 30 years, twice as much as forecasted with continued waterflooding. Besides, the updated reservoir model has been successfully employed to forecast polymer utilization, a valuable parameter to evaluate the pilot test’s economic efficiency. All the investigated development strategies indicate polymer utilization lower than 3.5 lbs/bbl in 30 years, which is economically attractive.
Oil Recovery Prediction for Polymer Flood Field Test of Heavy Oil on Alaska North Slope Via Machine Assisted Reservoir Simulation
The first ever polymer flood field pilot to enhance the recovery of heavy oils on the Alaska North Slope is ongoing. This study constructs and calibrates a reservoir simulation model to predict the oil recovery performance of the pilot through machine-assisted reservoir simulation techniques. To replicate the early water breakthrough observed during waterflooding, transmissibility contrasts are introduced into the simulation model, forcing viscous fingering effects. In the ensuing polymer flood, these transmissibility contrasts are reduced to replicate the restoration of injection conformance during polymer flooding, as indicated by a significant decrease in water cut. Later, transmissibility contrasts are reinstated to replicate a water surge event observed in one of the producing wells during polymer flooding. This event may represent decreased injection conformance from fracture overextension; its anticipated occurrence in the other production well is included in the final forecast. The definition of polymer retention in the simulator incorporates the tailing effect reported in laboratory studies; this tailing effect is useful to the simultaneous history match of producing water cut and produced polymer concentration. The top 24 best-matched simulation models produced at each stage of the history matching process are used to forecast oil recovery. The final forecast clearly demonstrates that polymer flooding significantly increases the heavy oil production for this field pilot compared to waterflooding alone. This exercise displays that a simulation model is only valid for prediction if flow behavior in the reservoir remains consistent with that observed during the history matched period. Critically, this means that a simulation model calibrated for waterflooding may not fully capture the benefits of an enhanced oil recovery process such as polymer flooding. Therefore, caution is recommended in using basic waterflood simulation models to scope potential enhanced oil recovery projects.
DOE/DOT Crude Oil Characterization Research Study, Task 2 Test Report on Evaluating Crude Oil Sampling and Analysis Methods, Revision 1 - Winter Sampling
The Crude Oil Characterization Research Study is designed to evaluate whether crude oils currently transported in North America, including those produced from “tight” formations, exhibit physical or chemical properties that are distinct from conventional crudes, and how these properties associate with combustion hazards that may be realized during transportation and handling. The current report presents results from Task 2, investigating which commercially available methods can accurately and reproducibly collect and analyze crude oils for vapor pressure and composition, including dissolved gases. This issue, Revision 1 – Winter Sampling, incorporates additional seasonal data and compositional analysis results that have become available since publication of a prior report, SAND2017-12482, released in December 2017. Both reports compare performance of commercially available methods to that of a well-established mobile laboratory system that currently serves as the baseline instrument system for the U.S. Strategic Petroleum Reserve Crude Oil Vapor Pressure Program. The experimental matrix evaluates the performance of selected methods for (i) capturing, transporting, and delivering hydrocarbon fluid samples from the field to the analysis laboratory, coupled with (ii) analyzing for properties related to composition and volatility of the oil, including vapor pressure, gas-oil ratio, and dissolved gases and light hydrocarbons. Several combinations of sample capture and analysis were observed to perform well in both summer and winter sampling environments, though conditions apply that need to be considered carefully for given applications. Methods that perform well from Task 2 will then be utilized in subsequent Task 3 (combustion studies) and Task 4 (compositional analyses of multiple crude types), to be addressed in subsequent reports.
Oil-Free Turbomachinery Team Passed Milestone on Path to the First Oil-Free Turbine Aircraft Engine
The Oil-Free Turbine Engine Technology Project team successfully demonstrated a foil-air bearing designed for the core rotor shaft of a turbine engine. The bearings were subjected to test conditions representative of the engine core environment through a combination of high speeds, sustained loads, and elevated temperatures. The operational test envelope was defined during conceptual design studies completed earlier this year by bearing manufacturer Mohawk Innovative Technologies and the turbine engine company Williams International. The prototype journal foil-air bearings were tested at the NASA Glenn Research Center. Glenn is working with Williams and Mohawk to create a revolution in turbomachinery by developing the world's first Oil-Free turbine aircraft engine. NASA's General Aviation Propulsion project and Williams International recently developed the FJX-2 turbofan engine that is being commercialized as the EJ-22. This core bearing milestone is a first step toward a future version of the EJ-22 that will take advantage of recent advances in foil-air bearings by eliminating the need for oil lubrication systems and rolling element bearings. Oil-Free technology can reduce engine weight by 15 percent and let engines operate at very high speeds, yielding power density improvements of 20 percent, and reducing engine maintenance costs. In addition, with NASA coating technology, engines can operate at temperatures up to 1200 F. Although the project is still a couple of years from a full engine test of the bearings, this milestone shows that the bearing design exceeds the expected environment, thus providing confidence that an Oil-Free turbine aircraft engine will be attained. The Oil-Free Turbomachinery Project is supported through the Aeropropulsion Base Research Program.
Estimating the reaction parameters of oil shale pyrolysis and oil shale grade using temperature transient analysis and inverse modeling
Grade of oil shale and reaction parameters of in-situ pyrolysis must be identified for the prediction of productivity before actual heating and production. Identification of oil shale grade and reaction parameters depends on laboratory experiments on core samples. However, laboratory-determined parameters can be different from those representing in-situ reservoir conditions. We use inverse modeling to determine oil shale grade and reaction parameters. The inversions are based on a forward model that simulates heat injection into a well. Temperature at the heating well is affected by a thermal skin effect as a result of a decrease of composite thermal conductivity around the heater due to the decomposition-induced porosity increase. Synthetic observations of heater temperature are generated from a forward simulation. Temperature difference and its derivative are used in synthetic inversions to estimate oil shale grade and parameters of active decomposition reactions with an error below 1%. Finally, the proposed methodology of inverse modeling is expected to successfully estimate the oil shale grade and reaction parameters without core sampling and subsequent surface experiments.
Data for Multisite Field Evaluation of Oil Accumulation and Agronomic Performance in Grain and Sweet Sorghums Engineered for Lipid Hyperaccumulation
Oil sorghum (OS) has been developed by engineering grain (TX430) and sweet (Ramada) genetic backgrounds to accumulate triacylglycerols (TAG) in vegetative tissues as an energy-dense feedstock for sustainable aviation fuel (SAF) and other biofuels. This study evaluated two TX430 OS lines (TxHO-2, TxHO-3) and two Ramada OS lines (RmHO-1, RmHO-2) alongside wild-type (WT) lines in NE and IL over 2 years (2023–2024) to quantify genotype × environment effects on agronomic performance and TAG accumulation. Across four environments, TX430 OS lines showed average TAG concentrations of 15.0 g kg−1 in leaves and 12.8 g kg−1 in stems, approximately 19-fold higher than WT. Ramada OS lines accumulated 26.1 g kg−1 in leaves and 12.3 g kg−1 in stems, approximately 25-fold and 13-fold increases over WT, respectively. OS lines in TX430 exhibited an 18% reduction in biomass (8.4 vs. 9.9 Mg ha−1 for WT), while Ramada OS lines had similar WT biomass (18.3 vs. 19.9 Mg ha−1 for WT). Among TX430 OS lines, TxHO-2 achieved the highest TAG yield (190 kg ha−1), while RmHO-1 led the Ramada lines (335 kg ha−1) due to higher biomass and similar TAG concentration. Enhanced TAG accumulation increased N, P, and K removal in TX430 lines but not in Ramada lines. Structural carbohydrate and ash concentration were unaffected. Overall, results confirm vegetative lipid accumulation as a viable strategy for high-biomass sorghum, supporting its potential as a dual-purpose feedstock for SAF. Future work should focus on minimizing biomass yield penalties and improving nutrient use efficiency in oil sorghum systems.