Product of the Week - Wind turbine lubrication products

Companies in the lubrication sector are currently expanding lubricant production lines to include the wind equipment that requires specialized lubricants. For instance, they may require certain blends of base oil and additives to cover different lubrication requirements of individual bearings in wind-power stations.

One trend has been towards reducing maintenance costs and simplifying lubrication routines in the nacelle. Also, as wind turbines are built higher and in more extreme conditions, the trend is towards using low-viscosity lubricants to address cold weather effects, produce more power, and decrease micropitting. Also, engineers are using special synthetics instead of mineral oils, along with particle counters to control contamination.

To reduce maintenance costs and simplify lubrication in the nacelle, operators are using single lubricants for all bearings. Bearings, seals, and lubricants are essential design elements when analyzing mechanical systems. Optimizing these elements leads to a more efficient, reliable system design. For example some high-performance lubricants have a blend of base oil and additives to cover different lubrication requirements of individual bearings. Adhesive grease lubricates gears in pitch and yaw drives, while reducing the risk of migration inside the nacelle and onto the tower.

Also, the industry has moved towards using synthetics instead of mineral oils to minimize maintenance. The lubricants tend to be well balanced, and have been widely tested in laboratory rigs and in the field. The preference for synthetics include high wear protection, higher efficiency from lower friction, and a wide operating temperature range. Specialty synthetic lubricants typically outperform mineral-based versions under the same conditions. Synthetics are further driven by a requirement for extended lubrication intervals.Synthetic gear oil also protects against micropitting, scuffing wear, and corrosion. Synthetic oils function over a wide temperature range and resist deposit formation. Furthermore, many new lubricants and greases extend oil change intervals from a matter of months to years, which significantly reduces maintenance costs.

The significance of reduced reliability and demands of operating wind farms in remote locations (on and offshore) and in harsh climates has been recognised by the sector. Sector engineers have developed a variety of lubricants to withstand extremely low temperatures and protect against micropitting and bearing wear. Another trend is to monitor the oil conditions, especially in gearboxes. For example, oil-analysis programs are being offered that can assist operators to monitor lubricant conditions along with equipment that helps in avoiding unscheduled downtimes.

Finally, particle counters provide contamination control for lubricants. Such units independently monitor system contamination trends, and act as early warning systems. LEDs or digital displays indicate low, medium, and high contamination levels. Such advancements, keep oil clean and increase equipment lifespan.

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