Wind turbines churn out power with tireless efficiency. They look simple enough on the outside, but the housing behind the blades contains massive gears and many complex moving parts, all meticulously synchronized and protected by a thin film of oil. These extraordinary machines demand specialized solutions to ensure optimal performance and prevent catastrophic failure.
Wind turbines experience immense pressure, shearing forces, variable loads and exposure to the elements constantly threatening to tear them apart. The lubrication system plays a crucial role in the safety, efficiency and longevity of this expensive machinery. Wind turbines typically require hundreds of gallons of high-quality gear oil to protect their massive gears from excessive wear and micropitting caused by the extreme pressure of constant rotation. A proper wind turbine lubrication program provides solutions to several challenges, which we are about to explore.
Challenges in Wind Turbine Lubrication
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Contamination
Contaminants are one of the most common issues in wind turbine lubrication. How is a gearbox 300 feet in the air exposed to contaminants that can harm the machine and the health of the lubricant? In desert or arid conditions, for example, airborne dust can get into gearboxes, act as an abrasive, and eventually lead to contact-fatigue failures.
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Moisture
Wind turbines are constantly subjected to changing weather. Water infiltration due to leaks or condensation can compromise oil performance and increase the risk of rust and corrosion.
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Temperature Extremes
Wind turbines commonly operate in harsh environments that experience a wide range of ambient temperatures, so they need high-quality lubricants that maintain their viscosity at extreme high and low temperatures under heavy pressure and at a variety of operating speeds.
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Lubricant Level and Supply
Wind turbine failures are often caused by neglecting to maintain the lubrication system. The correct level and supply of lubricants is vital to achieving optimum reliability.
Wind Turbine Lubrication Solutions
Properly formulated, high-quality synthetic lubricants can handle a wide range of temperature extremes, which improves turbine efficiency significantly. Synthetics also have higher resistance to mechanical shear, so they last longer than mineral oils.
Routine oil analysis is another key component for mitigating the challenges posed by the extreme wind turbine environment. Oil analysis is highly effective at identifying problems before they contribute to significant failures. By implementing regular analysis, using synthetic lubricants and taking proactive measures, these challenges can be effectively managed, ensuring the longevity and efficiency of your assets.
Ensure smooth, efficient turbine operation with a multi-pronged approach:
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The Right Lubricant: Selecting the optimal lubricant for the equipment and operating conditions is important.
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Lubrication Program: Proper oil level, filtration and maintenance play a vital role. Implementing condition-monitoring technologies and oil analysis can detect potential issues before they become catastrophic failures.
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AMSOIL Industrial Synthetic Power Transmission EP Gear Oil is available in multiple viscosities and is used in more than 40,000 heavily loaded gearboxes across several industries worldwide. It also exceeds industry standards for gearbox cleanliness, with an ISO 4406 cleanliness code of 16/14/11 at the time of packaging.
Let’s see how effective lubrication strategies translate to real-world scenarios:
Lab Testing
Borescope images confirm that AMSOIL Industrial Synthetic Power Transmission EP Gear Oil stopped the spread of micropitting wear that had formed using another brand of oil. After replacing the gear oil, the AMSOIL Industrial product prevented further micropitting and showed superior ability to eliminate foam, which improves wear protection.
“AMSOIL Industrial has a proven ability to extend wind turbine life in the most challenging environmental conditions. Leading turbine manufacturers and wind operators come to us when other lubricants fail.” —Brian Burks
Mastering Wind Turbine Lubrication
By understanding turbine lubrication challenges, deploying effective lubrication strategies and using AMSOIL Industrial lubricants, you can ensure that your wind assets will continue to churn out reliable and efficient power. Contact an AMSOIL Industrial Application Engineer to discuss custom solutions and start implementing your custom wind turbine lubrication program today.