Greases for wind turbines

A manufacturer of specialty lubricants has added two more for the wind-power industry: Klüberplex BEM 41-141 and Klüberplex AG 11-462. The first is a high-performance grease with a special blend of base oil and additives to cover different lubrication requirements of individual bearing applications in wind-power stations. The beige grease (BEM) is well suited for pitch and yaw bearings (high stresses, oscillations, vibrations), main bearings (low rpm, high stresses, vibrations), and generator bearings (high rpm and temperatures). A switch to one lubricant for all bearings reduces maintenance costs and simplifies lubrication routines. The second product is a priming and operational lubricant for open gears. Klüberplex AG 11-462, a white gear grease, provides excellent adhesion as well as superior protection against high loads and corrosion. The adhesive grease lubricates gears in pitch and yaw drives, while reducing the risk of migration inside the nacelle and onto the tower.

Klüber Lubrication

klubersolutions.com/wind

The wraps come off Lube&Seal sealing system

Wind turbines and all their components must be built to withstand a wide range of harsh environmentals. Even the smallest part, if poorly manufactured, can cause big problems. That’s why Simrit and Kluber Lubrication North America LP in Booth 9648, have combined their expertise to offer the Lube&Seal package, which provides the windpower industry the optimal combination of lubricants and seals.

The Lube&Seal sealing solution combines Simrit’s expertise in sealing technology and vibration control with Klüber’s knowledge in lubricants. This collaboration integrates sealing lips and lubricants into a more reliable tribological system for wind turbine gears.

“The partnership with Klüber lets us design, develop and manufacture a complete sealing system using the best possible materials and lubricants,” says Simrit President Dave Monaco. “As a result, we can provide clients with an all-in-one solution of the highest quality and durability.”

As an integrated system, the Lube&Seal helps minimize breakdowns in wind turbines due to leaks, while simultaneously preventing wear and reducing damage that can be caused by thermal instability and other environmental elements of particular concern to wind turbine manufacturers, such as the ozone, salty air and mineral oils.

“Repairs on wind turbines can be costly, difficult and dangerous,” says Jesse Dilk, industry group manager – wind, Klüber Lubrication North America L.P. “Therefore, it is vital to use high-quality components at every opportunity. Bearings, seals, and lubricants are essential design elements when analyzing mechanical systems. Optimizing these elements leads to a more efficient, reliable machine design.”

Synthetics Get More Work Out of Wind Turbines

Wind turbine nacelles are challenging environments for drivetrains. Input forces (wind captured by blades) can vary ±20% in the span of just three seconds. Unstable drivetrain foundations generate misalignments and additional stress. And the moisture levels and temperatures extremes outdoors are generally worse than in factories.

To minimize maintenance, lubrication trends have shifted from mineral oils to specialty synthetics. “The lubricants tend to be well balanced, and have been widely tested in laboratory rigs and in the field,” says Jesse Dilk , an engineer with Klüber Lubrication North America, Londonderry, N.H. (klubersolutions. com). “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,” he says.

The company provides three synthetic formulations for turbine equipment: Klübersynth GEM 2, GEM 4 N, and GH 6. “GEM 2 series is rapidly biodegradable, high-performance oil formulated from a synthetic ester. There is less interest today because of higher costs and industry standards,” he says.

The GEM 4 N series meets current gear requirements and represents an oil (polyalpholefin) widely used in the industry. “It has outstanding anti-foam properties, protects against micro-pitting, and contains no additives that might lead to residue formation,” adds Dilk.

The GH 6 series is based on polyglycols. “These provide the highest thermal  stability for longest oil life and the lowest friction coefficient of all the gear oil products that Klüber manufacturers for the wind energy industry. Past issues left some people in the industry with concerns regarding polyglycols and material compatibility. However, the issues have been solved with modern materials and components,” says Dilk.