SPECIALIST ENGINEERING FEATURE
40,000 GEARBOXES WORLDWIDE
PROVEN PERFORMANCE A US-based energy company realised significant performance and cost benefits by switching to ExxonMobil’s gearbox oil, Mobilgear SHC XMP 320. The mountaineer wind site operates forty-four turbines with a 66-megawatt (MW) output. The Flender Model PEAS 43090.5 gearboxes (60 gallon capacity) within the 44 NEG Micon1.5MW turbines were filled with Mobilgear SHC XMP 320 gear oil in 2002.
EXTREME CONDITIONS These gear boxes operate in an extreme four-season climate with temperatures ranging from -25°C in winter up to +40°C in summer. The operations, therefore, require a lubricant that could perform in tough applications across a wide temperature range, whilst also providing protection against micropitting and gearbox deposits.
HARD COST SAVINGS
As a result, the operator has reported hard cost savings of US $176,000 over seven years of service. This was largely achieved by extending oil drain intervals to twice the industry average for wind turbine gear boxes, saving $4,000 per turbine in reduced oil change maintenance costs. As part of its Signum oil condition monitoring programme, findings from the used oil analysis also showed excellent gear box cleanliness and better overall gear condition thanexpected, thereby helping to manage costs.
Due to results like this, Mobilgear SHC XMP 320 is now used to protect 40,000 gearboxes of wind turbines worldwide and is the initial-fill gear oil of choice for many of the world’s top wind turbine builders. In addition to its ability to maximise equipment performance and durability, the ability to extend the interval between oil changes from 18 months to three years or more can potentially make a big impact on reducing costs and difficult maintenance logistics. For example, this helps operators avoid the expense associated with replacement parts, labour and chartering specialist vessels to carry out the maintenance of offshore wind turbines.
UK’S GROWING WIND POWER INDUSTRY Closer to home, the latest additions to the company’s global customer base are three North Sea-based wind farms – Alpha Ventus, Borkum West and Thornton Bank, which demonstrates how these specialist lubricants are being relied upon by the UK’s growing wind power industry.
GETTING WARMED UP To complement the improved functionality of gearbox operations, Mobil SHC 500 hydraulic oils have been proven to offer energy efficiency benefits in hydraulic equipment. Compared to standard mineral hydraulic oils, Mobil SHC 500 can help to reduce hydraulic system energy consumption by up to 6.2 percent. This series was engineered to help protect hydraulic equipment operating in extremely cold conditions in offshore wind farms such as the North Sea or in remote onshore locations. At low temperatures Mobil SHC 500 is four times thinner than similar viscosity grade conventional mineral hydraulic oils*, allowing it to circulate around the hydraulic system faster at start up, ensuring the lubricant is in place to protect machine components. Although wind farms are unlikely to be exposed to such extreme arctic temperatures, the extent of the lubricant’s cold temperature performance demonstrates that operating within UK weather conditions and wind chill factors can be easily met.
COLLECTIVE RESULTS When combined with application expertise such as ExxonMobil’s Signum Oil Analysis Programme, which monitors the performance and health of the oil and components on an ongoing basis, the considered application of advanced lubricants to different components of wind turbines can achieve significant results.
Mobil Industrial
www.mobilindustrial.com Signum Oil Analysis
www.signumoilanalysis.com Click to view more info
* Based on comparative -400C Brookfield, ASTM D2893 test results, between Mobil SHC 525 and Mobil Univis N 46. For very low temperatures Mobil Aero HF or Univis HVI 26 may be considered depending on the Equipment Manufacturers Minimum Viscosity Startup requirements.
www.windenergynetwork.co.uk 89
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