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
