INNOVATION & NEW TECHNOLOGY FEATURE THE WINDS OF INNOVATION
The wind turbine industry is a driving force for advancing high-performance industrial lubricants, says Shell’s Joe O’Connor...
Advances in wind turbine technology have resulted in dramatic changes to standard gear oil used for wind turbines. The pressures wind turbines place on lubricants are now greater, and the operating conditions can be very harsh. To maintain a high level of operational reliability against the elements, and to keep up with industry technology advances, lubricants have had to become increasingly sophisticated.
RIGOROUS TESTING
Unique insight is being developed into the challenges of producing lubricant that meets the requirements of the wind turbine industry. It is an expensive process and involves more than 300 separate laboratory and rig tests before it is even considered for a field trial. These tests measure a multitude of parameters such as wear protection, load carrying capability, shear stability, resistance to foaming, filterability, and micropitting protection.
Clearly, developing a lubricant that meets the exacting standards of wind turbine equipment manufacturers is a substantial challenge, but it has led to a wide range of highly advanced lubricants that are used across other industrial sectors.
A GROWING POWER GENERATOR THAT NEEDS TOP PROTECTION Wind turbine installations and structures are increasing in size to maximise power generation capacities, and some turbines can stand up to 150m high and have a rotor span of 100m – this requires high durability lubricants to ensure maximum protection and smooth running of the machine.
Lubricant developments are helping to maximize returns on investment by reducing the costs of producing electricity from wind power. This is achieved through ensuring the equipment works reliably and requires minimal maintenance, as well as limiting downtime, in part through lubricants with longer operational life spans.
DESIGNED TO MEET CHALLENGES The main gearbox of a wind turbine, which drives the generator, comes under enormous strain every day, and reliability of the working functions is imperative. A major concern is gearbox micropitting, which results from factors such as case hardening and the surface roughness of the gear teeth, as well as inappropriate lubricant selection and application.
Given the gearbox’s size, the lubricant’s short recirculation times and the potential for air entrainment in the system, good air- release and anti-foaming characteristics are vital properties for the gear oil. Excessive foaming can cause the oil level to rise above the maximum, which may result in unplanned turbine shutdown and loss of power to the grid.
TEMPERATURE VARIANCE Further, wind turbines sit on top of high columns, and many installed units have to be robust enough to withstand both very high and very low temperatures. In the UK wind turbines have to contend with cold temperatures and wet weather which can lead to rusting. The rotors can also be static for periods of time, all of which place specific challenges on the lubricants to provide maximum protection for the longest time period.
SHELL OMALA S4 GX 320 To deal with all of these challenges Shell Lubricants has developed Shell Omala S4 GX 320, a synthetic gear oil that provides excellent performance in the areas requiring added protection against common failure modes, including micropitting and bearing wear. The product offers distinct advantages over conventional gear oils, particularly for product life. Field trials have shown it has up to four times the oil life of conventional mineral oil-based products, which enables the intervals between maintenance to be extended. The lubricant also gives excellent wear protection and is designed to reduce micropitting wear on gear teeth, which helps to extend the life of gearbox components and prolong operation.
A wind turbine’s lubricant-related challenges are not limited to the gearbox. The massive blades of a wind turbine are supported using grease-lubricated blade bearings that, if insufficiently lubricated, can fail through fretting and false brinelling. Again, the lubricant must be able to operate at temperature extremes and have corrosion-protection qualities.
SHELL RHODINA BBZ GREASE In reaction to this Shell formulated another lubricant from their experience in developing greases for helicopter rotors: Shell Rhodina BBZ grease. This is designed to protect bearings against fretting corrosion, moisture contamination, and false brinelling at temperatures as low as –55ºC.
Shell Rhodina BBZ is establishing a track record with both customers and major wind turbine manufacturers. It is lubricating the blade bearings of many wind turbines globally through listings with leading blade bearing suppliers including IMO, Liebherr, Rollix and Rothe Erde, and wind turbine manufacturers including Vestas, Acciona, Gamesa, Dongfang New Energy Equipment, Sinovel Wind Group, and Siemens Wind Power.
Joe O’Connor
Product Application Specialist Shell Lubricants
www.shell.com
www.windenergynetwork.co.uk
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