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DOE OSTI2021

Well Stimulation Treatment in California: Evaluation of Disclosure Data, May 2015 – October 2019

In this document, disclosure data from 1,228 well stimulations occurring May 2015 to October 2019 in California are evaluated. This evaluation updates a previous study that was based on 618 well stimulations occurring May 2015 to June 2016 (Stringfellow, W.T., Camarillo, M.K., and Jordan, P. 2017, Status of Well Stimulation in California Since Implementation of SB-4 Regulations, Berkeley National Laboratory, Berkeley, CA). While the goal of the previous study was to provide a summary of information obtained since passage of California Senate Bill No. 4—Oil and Gas, the goal of the current evaluation is to provide a basis for studying chemical indicators that could potentially be used to detect aquifer contamination. We evaluate chemical indicators is a separate document using the data contained herein as well as data from monitoring wells located within oil fields. Compared with the data used by Stringfellow et al. 2017, the current evaluation is based on a more diverse data set. While the previous study contained data for only two oil fields with more than 30 well stimulations, the current data set contains four oil fields with more than 30 well stimulations, making these data more ideal for comparisons using statistical tests. More producers and a new oil field, Buena Vista Nose, are represented in the current data set. Some well stimulation practices remain relatively unchanged since the previous study. Well stimulation is mostly occurring in Kern County with the exception of a single well stimulation in Orange County. Almost all well stimulations are hydraulic fracturing. The current data set contains two acid fracturing treatments and one matrix acidizing treatment. The median number of chemicals added per well stimulation—excluding water and proppant—was previously 21; the number in the expanded data set is 20. Median water added per well stimulation was previously 89,000 gallons and is now 98,000 gallons. While this water use represents a 10% increase, water use for hydraulic fracturing in California is still lower than water use in other oil and gas fields. Chemical formulations appear to have shifted since the previous study. This shift may be related to a change in the predominant service company. We identified 26 chemicals for which the frequency of use has changed by more than 30%. The total number of chemicals used has also expanded. Previously, 178 unique chemicals were identified as being added to well stimulation fluids. The total number of unique chemicals is now 205. Analytical data available for base and recovered fluids has expanded. The number of base fluid samples has increased from 12 to 35 and the number of recovered fluid samples has increased from 1,078 to 2,166. The expanded data set is more ideal for an evaluation of indicator chemicals and comparisons across different formations. The analytical data for recovered fluid samples indicates that many ions, radioactive constituents, and organics are consistently observed, making these chemicals ideal for consideration as potential indicators of aquifer contamination.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Strategic Petroleum Reserve Cavern Leaching Monitoring CY20

The U.S. Strategic Petroleum Reserve is a crude oil storage system run by the U.S. Department of Energy. The reserve consists of 60 active storage caverns spread across four sites in Louisiana and Texas, near the Gulf of Mexico. Beginning in 2016, the SPR began executing U.S. congressionally mandated oil sales. The configuration of the reserve, with a total capacity of greater than 700 MMB, requires raw water to be used instead of saturated brine for oil withdrawals such as for sales. All sales will produce leaching within the caverns used for oil delivery. Twenty-five caverns had a combined total of over 39 MMB of water injected in CY 20 as part of the Exchange for Storage program; oil was withdrawn in the same manner as for congressionally mandated sales. Leaching effects were monitored in these caverns to understand how the oil withdrawals may impact the long-term integrity of the caverns. While frequent sonars are the best way to monitor changes in cavern shape, they can be resource intensive for the number of caverns involved in sales and exchanges. An intermediate option is to model the leaching effects and see if any concerning features develop. The leaching effects were modeled here using the Sandia Solution Mining Code (SANSMIC) . The results indicate that leaching induced features are not of concern in the majority of the caverns, 19 of 25. Six caverns, BH-107, BH-113, BH-114, BM-4, BM-106, and WH-114 have features that may grow with additional leaching and should be monitored as leaching continues in those caverns. Ten caverns had post sale sonars that were compared with SANSMIC results. SANSMIC was able to capture the leaching well , particularly the formation of shelves and flares. A deviation in the SANSMIC and sonar cavern shapes was observed near the cavern floor in caverns with significant floor rise, a process not captured by SANSMIC. These results suggest SANSMIC is a useful tool for monitoring changes in cavern shape due to leaching effects related to sales and exchanges.

02 PETROLEUM↗

DOE OSTI2022

Carbon Intensities of Refining Products in Petroleum Refineries with Co-Processed Biofeedstocks

Petroleum refineries increasingly seek to generate fuels with lower carbon intensities (CIs; a measure of life cycle greenhouse gas [GHG] emissions per unit of energy of fuel; well-to-wheel [WTW]) to meet growing demand. Co-processing refers to a process that adds biomass-derived feedstocks to the fossil-based feedstocks of existing petroleum refinery process units. With the use of biofeedstocks, it is expected that co-processed fuels would have lower CIs than their petroleum counterparts without requiring changes in the existing infrastructure for producing, transporting, and using fuels. To quantify the GHG emissions reduction benefits of co-processing, this study uses a linear programming model to simulate petroleum refinery conditions with and without co-processing. The co-processing cases include three biofeedstocks (soy oil, tallow, and used cooking oil or UCO) used as 10 vol.% of the feedstock to a hydrotreater or hydrocracker since these lipid-based feedstocks have favorable properties to be treated in a hydrotreater or hydrocracker. In addition, we considered pyrolysis oil used as 10 vol.% of the feedstock to a fluid catalytic cracking (FCC) unit in the modeled refinery due to its higher oxygen content compared to other lipid-based feedstocks. Life cycle analysis (LCA) using two distinct approaches—process-level energy allocation and a refinery-level marginal approach—has been conducted for each case. The LCA results using process-level allocation show that there are no noticeable changes in emissions or energy use impacts at the facility level. The life cycle GHG emission reductions of co-processing cases are mainly related to the fraction of biogenic carbon embedded in each fuel product. For example, co-processed jet fuels (a mixture of fossil and biogenic fuels) made via hydrotreating or hydrocracking have higher biogenic carbon, which results in jet fuel CI reductions of 3.9%–8.6% compared to the CI of baseline petroleum jet fuels on a WTW basis. However, analysis of co-processed pyrolysis oil in an FCC shows that a higher fraction of biofeedstocks (29%) becomes process emissions (i.e., CO and CO 2 ), mainly due to the oxygenates in pyrolysis oil, and so it generates less renewable fuel than biofeedstocks co-processed via hydrotreating or hydrocracking. Using the refinery-level marginal approach, the changes in energy use and emissions of co-processing cases compared to the petroleum-only baseline case are allocated to the changes in fuel production (assuming renewable fuels). This approach generates the life cycle GHG emission values of co-processed renewable fuels, which are comparable to the CIs of standalone biofuel production pathways. However, as this approach relies on a rough assumption that product yields and emissions from co-processing units on fossil feedstocks remain the same with and without biofeedstock inputs, co-processing cases like FCC pyrolysis oil may generate quite skewed results.

02 PETROLEUM↗

DOE OSTI2022

Resource Recovery and Environmental Protection in Wyoming’s Greater Green River Basin Using Selective Nanostructured Membranes (Final Report)

Produced water (PW) represents a sizable waste stream that is co-generated with oil and natural gas production. In 2021 Wyoming ranked 8th and 9th, respectively in domestic oil and natural gas production. In 2017 Wyoming ranked as the 4th highest generator of PW in the U.S, accounting for 7% of the total volume generated. In the context of being the 3rd most arid state in the U.S., the value of water reuse becomes obvious. PW reuse, and resource recovery, in any form requires some level of treatment to remove particulates, residual (free, dispersed) hydrocarbons, organics, and salts. The level of treatment depends on the requirements of the reuse, or resource recovery, application. PW management systems in Wyoming employ in order of volume of PW managed the following management strategies: reinjection for enhanced oil recovery, surface discharge, deep well injection, evaporation ponds (impoundments), and commercial management/treatment. Complicating treatment efforts are the relatively high concentrations of organics (natural and synthetic), dispersed/free hydrocarbons, benzene-toluene-ethylbenzene, and xylenes (BTEX) compounds, biologicals, salts, and minerals. Hydrocarbons (dispersed/dissolved crude oils) and BTEX compounds, as well as synthetic organics, present economic and environmental concerns. The former represents lost revenue, while the latter results in negative environmental impacts like emissions from surface impoundments. The overall objective of this proposal was to synthesize superhydrophilic/oleophobic and superhydrophobic/oleophilic membranes for selectively concentrating and then separating BTEX compounds and oil and grease (O&G) from PW originating from the Greater Green River Basin (GGRB) in Wyoming. Three specific research aims were pursued to accomplish this overall objective. This final report details the development of the superhydrophobic and superhydrophilic membranes, as well as the design of the membrane module prototypes specifically. The technoeconomic assessment is separately reported in another document. 1. Aim #1 – Material optimization and performance evaluation of superhydrophilic/oleophobic and superhydrophobic/oleophilic membranes made by electrospinning/spraying. 2. Aim #2 – Design and construction of cross-flow membrane modules for selectively concentrating and then separating BTEX/oil from GGRB produced water. 3. Aim #3 – Techno-economic assessment of BTEX/oil recovery, and clean water production, using superhydrophilic/oleophobic and superhydrophobic/oleophilic membrane separation for GGRB PW. Superhydrophobic membranes were synthesized by electrospinning poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP) nanofibers onto polyester (PET) substrates and electrospraying nano-carbon black/PVDF-HFP onto the nanofibrous layer. These membranes were characterized by high (>8000 liters per square meter per hour per bar (LMH/bar)) permeance values for pure hydrocarbon phases and a high hydrocarbon selectivity (>96%) when treating GGRB PW. All results were obtained when operating the membrane in a crossflow configuration representative of actual field operating conditions. Solvent/oil properties, specifically viscosity and total surface energy/tension, affected permeance across the membrane, which resulted in light mineral oil (394 LMH/bar) and o-xylene (1834 LMH/bar) being characterized by lower permeance values in the pure phase tests. Mixed phase fluxes between 40 to 80 LMH were obtained for the PW when operating the membrane at a feed pressure of 0.3 bar. Flux decreased as the mixed phase concentration in the feed decreased pointing to the importance of maximizing the collision efficiency between the emulsion and the membrane surface and maximizing the emulsion concentration in the feed and the turbulence within the feed channel. These tests demonstrated that the superhydrophobic membranes developed here are a viable hydrocarbon recovery method for GGRB PWs and should be pursued for testing in pilot-scale trials. Superhydrophilic membranes were successfully synthesized via electrospinning/spraying using polyacrylonitrile (PAN) nanofibers as a base nanofibrous matrix. Integration of polyaniline (PANI) into the nanofibrous matrix produced a superior membrane, for water filtration applications, relative to PAN alone and reduced graphene oxide (RGO) when integrated into the nanofibrous matrix. This conclusion was based on the PANI-PAN resistance to flux loss (fouling) when treating model solvent/oil solutions representative of GGRB PWs and field collected PW from the GGRB. The synthesized PAN membranes outperformed a commercially available PAN membrane designed for oil/water separation. This finding indicates that the surface chemical and physical characteristics of the electrospun membranes presents improved properties for filtration of challenging waters like GGRB PWs. The electrospun membranes therefore show promise overall as a substitute for conventionally polymerized membranes in PW treatment applications. The PANI-PAN membrane specifically presents superior performance characteristics for concentration O&G prior to treatment by the hydrocarbon recovery membrane and producing high-quality filtrate for reuse and/or additional treatment (desalination).

02 PETROLEUM↗

DOE OSTI2024

EOR in Shale Resources

This work provides an overview of the research conducted at NETL and the University of Pittsburgh related to improving the perfornace of CO2 huff-and-puff enhanced oil recovery (EOR) in fractured shale and fractured tight formations. CO2-soluble wettability-altering surfactants will be dissolved in high pressure CO2 during the "huff" stages in an attempt to shift the wettability of shale surfaces away from oil-wet toward CO2-wet. Such a change should promote additinal oil recovery during the depressurization of the formation that occurs during the "puff" stages. Surfactant soubility in CO2, CO2-oil IFT, CO2-rock-oil contact angle, and core-scale huff and puff oil recovery results are presented.

Enick, Robert↗

DOE OSTI2024

Creating Accurate Methane Emission Inventories through Data-Driven Airborne Survey Strategies: Methods and Results from the Haynesville, Anadarko, and Permian Basins

Significantly reducing methane emissions from the oil and gas sector can decrease the rate of climate change over the next two decades, buying critical time for a global energy transition. However, emissions inventories that can be used by oil and gas operators and environmental regulators to identify optimal methane emission mitigation strategies are either based on conservative emission factor methods, or are inconsistent between studies due to differences in sampling strategies or survey technologies. We developed a new approach for methane emissions survey design that yields representative basinwide methane emissions inventories by surveying a subset of total assets in a given oil and gas basin. We identify several sampling and analysis principles, including large sample sizes, balanced sampling across oil and gas production, careful survey area definition, and a unified protocol for analysis, to be vital to producing an unbiased estimate of basin-scale emissions that can be reconciled with future studies. We further present results from deploying this strategy in two oil and gas producing regions in the United States: the Haynesville Basin in Texas and Louisiana, and the Woodford Shale in the Anadarko Basin in Oklahoma. Aerial surveys were performed in 2023 using the Insight M LeakSurveyor™ technology. Preliminary results from methane emissions detected by Insight M indicate that aerially detected emissions above roughly 30 kg(CH4)/hr by themselves contribute a fractional loss rate of 1.13% of gross gas production across oil and gas operations in the Haynesville Basin, with aerially detected emissions equivalent to 2.67% of gross gas production in the Woodford Shale. We supplement these aerial estimates with modeled emissions that are below the LeakSurveyor’s survey sensitivity using a recently published inventory-based model of methane emissions, which we update for our survey areas. We then combine our aerial detections with modeled emissions to yield methane emission distributions and inventories that incorporate the full range of potential methane emissions from the smallest to the largest. These results can be used to identify the most effective methane mitigation strategies for our study areas, and can be reconciled with future methane emissions surveys that use different technologies.

Sherwin, Evan (ORCID:0000000321804297)↗

NASA NTRS1973

Thermal death of a hydrocarbon bacterium in a nonaqueous fluid

A hydrocarbon-utilizing Brevibacterium which grew into the oil phase of an oil-water system was tested for survival at elevated temperature. Cells suspended in oil and cells that had been resuspended in aqueous solution were tested by placing 1-ml samples of the cell suspension in small test tubes immersed in a controlled-temperature water bath. The resultant survival curves in oil consisted of two parts, a flat shoulder obtained in the first half of the heating period, followed by a break indicating rapid die-off. The break in the curves occurred after 50% of the cells were killed. This occurred at exposures of 25, 15, and 8 min for 78, 88.6, and 96.2 C, respectively. The survival curve for 63.5 C in the aqueous solution was a rapid, exponential die-off. The actual increase in survival of the organism in oil is reflected by the length of the shoulder portion. The shoulder occurs only in an oil medium and is increased by decreasing temperature and increasing age of the culture.

Severance, M. M.↗

NASA NTRS1979

Satellite monitoring of sea surface pollution

The author has identified the following significant results. Image processing techniques developed are well adapted to the exploration and isolation of local areas which exhibit small temperature differences between themselves and their surroundings. In the worst case of imagery of small areal extent of sea surface having no coastal boundary in the area, there is yet no method of distinguishing unambiguously an oil spill from fog, cloud, the effect produced by shallow sediments, or the effects of naturally occuring thermal fronts. In the case of uniform slicks of liquid North Sea oil in still air, laboratory simulation experiments show that, for oil thicknesses in excess of 1 or 2 mm, there is, under equilibrium conditions, little dependence of oil surface temperature on the thickness of the oil layer. The surface temperature of oil is consistently higher than that of water, the difference being about 1 K at low values of relative humidity, but tending to increase as the relative humidity increases.

Fielder, G.↗

NASA NTRS1984

Lubricant Rheology in Concentrated Contacts

A revue of experimental investigations of lubricant behaviour in highly stressed situations shows that a Newtonian model for lubricant rheology is insufficient for explanation of traction behaviour. The oil film build-up, on the other hand, is fairly well predicted using a Newtonian lubricant model except at high slide to roll ratios and at very high loads, where the non-Newtonian behaviour starts to be important already outside the Hertzian contact area. Two main types of experiments are reported: static and dynamic. In static experiments the pressure is typically applied to the lubricant more than a million times longer than in an EHD contact. Depending on the pressure-temperature history of the experiment the lubricant will become a crystallized or amorphous solid at high pressures. In dynamic experiments, where the pressure is applied as short time as in real EHD contacts, the oil is in an amorphous solid state. Depending on the viscosity, time-scale, elasticity of the oil and the bearing surfaces, the oil film pressure, shear strain rate and the type of lubricant, different properties of the oil are important for prediction of shear stresses in the oil. This can be seen from the different proposed models for the lubricant, where it is described as being for instance a Newtonian liquid, an elastic liquid, a plastic liquid and an elastic-plastic solid.

Bo O Jacobson↗

NASA NTRS1984

Effect of lubricant extreme-pressure additives on surface fatigue life of AISI 9310 spur gears

Surface fatigue tests were conducted with AISI 9310 spur gears using a formulated synthetic tetraester oil (conforming to MIL-L-23699 specifications) as the lubricant containing either sulfur or phosphorus as the EP additive. Four groups of gears were tested. One group of gears tested without an additive in the lubricant acted as the reference oil. In the other three groups either a 0.1 wt % sulfur or phosphorus additive was added to the tetraester oil to enhance gear surface fatigue life. Test conditions included a gear temperature of 334 K (160 F), a maximum Hertz stress of 1.71 GPa (248 000 psi), and a speed of 10,000 rpm. The gears tested with a 0.1 wt % phosphorus additive showed pitting fatigue life 2.6 times the life of gears tested with the reference tetraester based oil. Although fatigue lives of two groups of gears tested with the sulfur additive in the oil showed improvement over the control group gear life, the results, unlike those obtained with the phosphorus oil, were not considered to be statistically significant.

Scibbe, H. W.↗

NASA NTRS1989

Thermocapillary migration of liquid droplets in a temperature gradient in a density matched system

An experimental investigation of thermocapillary flow in droplets of a vegetable oil (partially hydrogenated soybean oil) immersed in silicone oil was conducted in a test cell with a heated top wall and a cooled bottom wall. The liquids are nearly immiscible and have equal densities at a temperature below the room temperature, thus providing a simulation of low-gravity conditions by reducing the buoyancy forces. The interfacial tension between the two oils was measured in the temperature range 20 to 50 C using a capillary tube and (d sigma)/(d T) was determined to be negative. Droplets ranging in sizes from 3 mm to 1 cm diameter were injected into the silicone oil. The vertical temperature profile in the bulk liquid (silicone oil) produces temperature variations along the interface which induce variations in the interfacial tension. The flow inside the droplet driven by the resulting interfacial shear stresses was observed using a laser light-sheet flow visualization technique. The flow direction is consistent with the sign of (d sigma)/(d T). The observed maximum surface velocities are compared to the theoretical predictions of Young et al. (1959).

Rashidnia, N.↗

NASA NTRS1991

Thermocapillary migration of liquid droplets in a temperature gradient in a density matched system

Rashidnia, N.↗

NASA NTRS1932

Investigation of Damping Liquids for Aircraft Instruments : II

Data are presented on the kinematic viscosity, in the temperature range -50 degrees to +30 degrees C. of pure liquids and of solutions of animal oils, vegetable oils, mineral oils, glycerine, and ethylene glycol in various low freezing point solvents. It is shown that the thermal coefficient of kinematic viscosity as a function of the kinematic viscosity of the solutions of glycerine and ethylene glycol in alcohols is practically independent of the temperature and the chemical composition of the individual liquids. This is similarly true for the mineral oil group and, for a limited temperature interval, for the pure animal and vegetable oils. The efficiency of naphthol, hydroquinone, and diphenylamine to inhibit the change of viscosity of poppyseed and linseed oils was also investigated.

Houseman, M R↗

NASA NTRS1995

Surface inspection using FTIR spectroscopy

The use of reflectance Fourier transform infrared (FTIR) spectroscopy as a tool for surface inspection is described. Laboratory instruments and portable instruments can support remote sensing probes that can map chemical contaminants on surfaces with detection limits under the best of conditions in the sub-nanometer range, i.e.. near absolute cleanliness, excellent performance in the sub-micrometer range, and useful performance for films tens of microns thick. Examples of discovering and quantifying contamination such as mineral oils and greases, vegetable oils, and silicone oils on aluminum foil, galvanized sheet steel, smooth aluminum tubing, and sandblasted 7075 aluminum alloy and D6AC steel. The ability to map in time and space the distribution of oil stains on metals is demonstrated. Techniques associated with quantitatively applying oils to metals, subsequently verifying the application, and non-linear relationships between reflectance and the quantity oil are described.

Powell, G. L.↗

NASA NTRS2013

Performance and Analysis of Perfluoropolyalkyl Ether Grease Used on Space Shuttle Actuators--A Case Study

Actuators used on the United States space shuttle fleet are lubricated with unspecified amounts of Braycote 601 (Castrol Braycote) grease consisting of a perfluoropolyalkyl ether (PFPAE) base oil thickened with a polytetrafluoroethylene (PTFE) filler. Each shuttle has four body flap actuators (BFAs) (two on each wing) on a common segmented shaft and four rudder speed brake (RSB) actuators. The actuators were designed to operate for 10 years and 100 flights without periodic relubrication. Visible inspection of two partially disassembled RSB actuators in continuous use for 19 years raised concerns over possible grease degradation due to discoloration of the grease on several places on the surfaces of the gears. Inspection revealed fretting, micropitting, wear and corrosion of the bearings and gears. A small amount of oil dripped from the disassembled actuators. Whereas new grease is beige in appearance, the discolored grease consisted of both grey and reddish colors. Grease samples taken from the actuators together with representative off-the-shelf new and unused grease samples were analyzed by gravimetry for oil content; by inductively coupled plasma spectroscopy (ICP) for metals content; Fourier transform infrared (FTIR) spectroscopy for base oil decomposition; and by size exclusion chromatography (SEC) for determination of the molecular weight distributions of the grease oil. The Braycote 601 grease was stable after 19 years of continuous use in the sealed RSB actuators and was fit for its intended purpose. There were no significant chemical differences between the used grease samples and new and unused samples. Base oil separation was not significant within the sealed actuators. No corrosive effect in the form of iron fluoride was detected. The grey color of grease samples was due to metallic iron. The red color was due to oxidation of the metallic wear particles from the gears and the bearings comprising the actuators.

Morales, Wilfredo↗

NASA NTRS2012

Pristine Stratospheric Collections of Cosmic Dust

Since 1981, NASA has routinely collected interplanetary dust particles (IDPs) in the stratosphere by inertial impact onto silicone oil-coated flat plate collectors deployed on the wings of high-altitude aircraft [1]. The highly viscous oil traps and localizes the particles, which can fragment during collection. Particles are removed from the collectors with a micromanipulator and washed of the oil using organic solvents, typically hexane or xylene. While silicone oil is an efficient collection medium, its use is problematic. All IDPs are initially coated with this material (polydimethylsiloxane, n(CH3)2SiO) and traces of oil may remain after cleaning. The solvent rinse itself is also a concern as it likely removes indigenous organics from the particles. To avoid these issues, we used a polyurethane foam substrate for the oil-free stratospheric collection of IDPs.

Messenger, S.↗

NASA NTRS2017

Experimental Investigation of Shrouding on Meshed Spur Gear Windage Power Loss

Windage power loss in high-speed gearboxes results in efficiency losses and increased heating due to drag on the gear teeth. Test results for meshed spur gear windage power loss are presented at ambient oil inlet temperatures, both with and without shrouding. The rate of windage power loss is observed to increase above a gear surface speed of 10,000 feet per minute (51 meters per second), similar to results presented in the literature. Shrouding is observed to become more effective above 15,000 feet per minute (76 meters per second), decreasing power loss by 10 percent at 25,000 feet per minute (127 meters per second). The need for gearbox oil drain slots limits the effectiveness of shrouding in reducing windage power loss. Windage power loss is observed to decrease with increasing gearbox temperatures and to increase with oil flow. Windage power losses for unshrouded meshed spur gears are 7 times greater than losses determined from unshrouded single spur gear tests. A 6- to 12-times increase in windage power loss is observed in the shrouded meshed spur gear data compared with shrouded single spur gear data. Based on this preliminary study, additional research is suggested to determine the effect of oil drain slot configurations, axial and radial shroud clearances, and higher gear surface speeds on windage power loss. Additional work is also suggested to determine the sensitivity of windage power loss to oil temperature and oil flow. Windage power loss for meshed spur gears tested in both the shrouded and unshrouded configurations is shown to be more than double versus windage power loss for the same spur gears run individually in the same shroud configurations. Further study of the physical processes behind these results is needed to optimize gearbox shrouds for minimum windage power loss.

drag↗

NASA NTRS2017

Experimental Investigation of Shrouding on Meshed Spur Gear Windage Power Loss

Windage power loss in high-speed gearboxes result in efficiency losses and increased heating due to drag on the gear teeth. Meshed spur gear windage power loss test results are presented at ambient oil inlet temperatures both with and without shrouding. The rate of windage power loss is observed to increase above 10,000 ft.min., gear surface speed, similar to results presented in the literature. Shrouding is observed to become more effective above 15,000 ft.min., decreasing power loss by 10 at 25,000 ft.min. The need for gearbox oil drain slots limits the effectiveness of shrouding on reducing windage power loss. Also, windage power loss is observed to decrease with increasing gearbox temperatures and to increase with oil flow. Windage power losses for the unshrouded meshed spur gears are 7x more than losses determined from unshrouded single spur gear tests. A 6x to 12x increase in windage power is observed comparing shrouded single spur gear data with shrouded meshed spur gear data. Based on this preliminary study additional research is suggested to determine the effect of oil drain slot configurations, axial and radial shroud clearances, and higher gear surface speeds on windage power loss. Additional work is also suggested to determine the sensitivity of windage power loss to oil temperature and oil flow. Windage power loss of meshed spur gears tested in both the shrouded and unshrouded configurations is shown to be more than double versus the same spur gears run individually in the same shroud configurations. Further study of the physical processes behind these results is needed for optimizing gearbox shrouds for minimum windage power loss.

gear↗