By Mike Blumenfeld, Industrial Lubricant Development and Wind Industry Specialist, ExxonMobil Product Solutions 

Recent supply uncertainties have meant that the pressure on wind farm operators to perform – and make the right choices – has never been greater. There’s been much talk about bigger turbines and blade recycling, but the smaller details matter too. 

Every component that moves in a wind turbine requires a lubricant to reduce friction, remove heat and prevent wear. Despite this, and the fact that operations and maintenance costs account for 18-26% of the lifetime cost of wind energy, the role played by high-performance oils and greases can sometimes be underplayed. 

The truth is that, throughout its history, advanced lubricants have been a key problem solver for the wind power sector. This is particularly true when it comes to one of the main drivers of wind turbine maintenance: the gearbox.  

A history of problem-solving 

In the 1990s, turbine and gearbox OEMs looked to lubricant formulators to help them address the problem of micropitting which was curtailing gear life. In the early 2000s, as installations in cold climates became more common, focus shifted to the need for high-viscosity index basestocks with enhanced low temperature fluidity. This heralded the invention of metallocene catalyzed PAO base stocks, or mPAO, which remain the industry standard today. 

In the 2010s, to reduce bearing failures, understanding and preventing white etching cracking (WEC) became a priority, leading to the development of Mobil SHC™ Gear 320 WT – the first lubricant certified by DNV to not contribute to the formation of WEC. 

These advancements have paved the way for better-performing, longer-lasting turbines. The next frontier lies in pushing these innovations further, – towards ‘fill-for-life technology’ – an innovation that could save the wind industry billions of dollars over the next 30 years. And is already here.

Making lifetime lubrication a reality 

Over six years of intensive research, accelerated life testing, and optimisation have gone into developing a gear oil designed to last the lifetime of a wind turbine. The result is Mobil SHC™ Gear 320 WindPower, a gear oil that builds on a legacy of innovation in the field. 

Mobil SHC Gear 320 WindPower is an advanced formulation, engineered with advanced base oils and carefully selected additives to provide strong resistance to white etching cracks (WEC), micropitting, and scuffing. 

To ensure optimum performance for the lifetime of a wind turbine, ExxonMobil will supply operators with ongoing lubrication management services – advising on and supplying the appropriate top treat regime. Mobil Xtra™ WT Series top treat solutions are engineered to help extend oil life in wind turbine gearboxes, allowing customers to protect their investment while avoiding challenging oil change outs.

DNV-certified to achieve more with less 

Mobil SHC Gear 320 WindPower and Mobil Xtra™ EP WT top treat have been certified by DNV to deliver outstanding performance and protection for the lifetime of a wind turbine (DE-DNV-SE-0074-10516-1) and is now available to WT OEMs for specifications testing ahead of full commercialisation. 

Keeping a single turbine in operation can require up to 1,400 litres of lubricant. As such, this innovation will not only help reduce operational and maintenance costs. It also has the potential to support the wind industry’s sustainability ambitions by reducing oil usage and waste.

By offering lifetime oil drain interval (ODI) capability, the product can deliver an estimated 80% reduction in Global Warming Potential (GWP) when compared to a product with an ODI of 5 years. 

Collaborative innovation 

Today, as the demand for long drain intervals and reliable performance in extreme conditions continues to grow, the lubricants supporting the system must be able to handle larger loads from larger turbines in smaller gearboxes. And handle them for longer. 

A key driver of innovations in our Mobil™ brand is our close collaboration with industry bodies and leading OEMs to understand equipment trends and requirements, consult on lubrication system designs, and troubleshoot field lubrication challenges.  

Being an APQP4Wind Company Member, meanwhile, is an important part of our commitment to standardised quality and process simplification, guaranteeing consistent standards across the wind industry. 

Tailored solutions 

The Mobil range of high-performance synthetic oils and greases is formulated to protect critical components and enhance wind turbine availability and is supported by extensive equipment builder approvals. This explains why Mobil products are used in approx. 1 in every 4 wind turbines worldwide. 

To help wind customers achieve peak productivity, we also offer a full suite of services designed to help optimize equipment performance and oil drain intervals. These include Wind Turbine Gearbox Flush and Fill, start-up and cleanliness guidance, as well as Mobil Lubricant Analysis, with a program specifically tailored to wind turbine applications. 

These solutions are complemented with hands-on guidance and application expertise from the company’s team of skilled engineers, dedicated to helping wind turbine operators reach new levels of safety and environmental care, as well as productivity. 

To learn more about Mobil’s wind energy offer, visit mobil.eu/wind  

Avrasya Rüzgar, offering repair and maintenance services for wind turbines, blades, towers, and tower interior equipment, provides solutions for globally leading companies. The company is a solution partner in the wind energy industry with its experienced and expert team. Avrasya Rüzgar General Manager Buğra Akbıyık shared the details of their services and goals with Rüzgar Enerjisi Magazine in the interview we conducted.

Could you please inform us about your experience in the Wind Energy market in Turkey?

Eawind (Avrasya Rüzgar) was established in 2010 as the successor of KompoTek, Composite Technologies, which had many years of experience in composite blade and mold production as well as composite boat building. With this experience, Eawind began serving international customers for their turbines in Turkey in 2010 for blade service, being one of the first in the market.

What services do you offer to your customers?

The main services we offer are “blade repair” and “blade retrofitting.” As a wind turbine gets older, like a human being, the components such as blades, which are exposed to environmental changes, age, leading to the need for repairs. We also provide tower repairs and coatings as well as tower internal works, such as servicing hoists, winches, and ladder systems.

How are your technicians trained?

We have our own training center and are licensed to conduct GWO (Global Wind Organisation) trainings. We train and license our technicians in “Blade Repair” and “Basic Safety Training.” Additionally, we provide other extra internal trainings that our technicians undergo. Depending on our customers’ requests, there are also external training opportunities for our technicians.

Are these trainings open to other companies?

Yes, we offer GWO Blade Repair and GWO BST modules to other companies as well as freelance technicians. Our Training Center is in Izmir, Turkey, which is a perfect seaside location with direct flights to many European cities. We welcome many trainees from Germany and Greece as well as countries from the Middle East and North Africa.

Who are your main customers and partners in your region and in Europe?

We are an approved ISP (International Service Provider) for Enercon, NordexAcciona, and SiemensGamesa Renewable Energy. Our technicians are trained to the highest standards by these companies. We also service Vestas, GE, Suzlon, and Sinovel turbines mostly on the customer side. Windsourcing of Hamburg is one of our partners in Europe, from whom we supply materials for servicing, and we offer our customers their product range. With our storage capabilities, we can keep composite raw materials for our customers. We also work with Mankiewicz Coatings of Hamburg, which has a location and storage capabilities in Turkey. This is extremely helpful when transporting chemical materials to Turkey is sometimes challenging.

What were the important steps your company took in the past to improve service quality?

Starting from 2014, we were the first company to use Temporary Suspended Platforms (TSPs) for working on the blades and towers of wind turbines. Understanding the importance of platforms, we joint-ventured with a German company and produced these platforms in our production line in Izmir. We are currently working on a new platform design aimed at increasing the efficiency of servicing time. Additionally, we were one of the first companies to establish our own Training Facility for our technicians, including GWO accreditation and other ISO accreditations. I believe these were the most important steps to improve service quality.

Are you planning service operations in Europe as well?

As an ISP for major turbine manufacturers like Enercon and NordexAcciona, we are eager to serve customers in Europe. Through our Germany-based company, Eawind GmbH, we provide comprehensive services to Europe.

We would like to thank Rüzgar Enerjisi Magazine for the interview.

TUİZ Wind, which was founded in 2021 in order to provide services for installation, maintenance and service projects, which are essential parts of the wind energy industry, provides innovative wind solutions and reshapes the future of the industry with the experience of its founders and employees in the energy industry for many years. With its experience in many installation, maintenance and service projects in different locations around the world, TUİZ has made a considerable contribution to the industry and keeps a close eye on new technologies to ensure a higher standard of service that is open to development and to contribute to the advancement of the industry. The company aims to become a pioneer in the global energy industry by reshaping the wind energy future, and to this end, it offers solutions with cutting-edge technology and engineering. With customer satisfaction and trust at the core of its solutions, the references of TUIZ include industry-leading organizations like Borusan Logistics, Enercon, SOWI, Vestas, Sarılar Group, General Electric, Kalyon, Nordex, Siemens Gamesa, Goldwind, Senvion and LEITWIND.

Specialist TUIZ solutions

Installation:

TUİZ, which provides installation services with a dedicated team with more than 15 years of experience in Enercon, Vestas, Siemens, GE and Nordex wind turbines, carries out the installation of all types and models of wind turbines and undertakes project management from scratch.

Service maintenance:

In order to identify damages or problems in the early stages and reduce the time for repair and downtime to a bare minimum, it is necessary to conduct repeated inspections and maintenance of all components of a wind turbine. In this area, TUİZ provides a premium level of service and carries out all the maintenance in line with the manufacturer’s maintenance guidelines.

Network connection service:

TUİZ, ensures that all operations such as in-turbine cable connections, cable installation, panel connections, transformer connections, and other operations are conducted securely and in a high-quality manner with its specialized team of technical experts.

Main Component Replacement:

The turbines’ key parts such as the generator, gearbox, rotor blade, powertrain, yaw/pitch system, transformer, and top tower parts must be upgraded during their lifetime. TUİZ’s highly experienced upgrade team quickly and efficiently performs this demanding task.

Technical support:

During the project duration of the wind farm, the company provides support to its customers through its supervisors.

Disposal:

The specialized TUİZ technical team also provides solutions for the recycling of the blades.

Port and site operations:

TUİZ conducts loading/unloading activities on project sites, production plants and port plants in a safe manner with the sling and pointer training certificates of the technical crew.

Turbine supervision:

The inspection of turbines is performed through unplanned interim checks, observations before and after maintenance, and reports are shared with clients.

Service elevator installation:

The specialized TUİZ technical team also offers installation services for service elevators and conducts annual inspections.