Gear Oils and Oil Sensor Technology
Additive Technology for the 21st Century
Imagine a wind farm: dozens of windmills, sleek and modern, delivering clean, efficient energy. Now, imagine that you are the person in charge of keeping those turbines running smoothly. The cost of an oil change—per turbine—is estimated at roughly $15,000 (USD), with each change taking between 50 to 100 gallons of gear oil. Some current guidelines recommend fluid changes every 18 months for mineral oils and every two years for synthetic oils; others stretch the limit to three to five years. In any case, the demand for upgraded lubricants and high value lubricant additive chemistry will grow as wind turbines continue to evolve.
A Full Range of Benefits and Field Proven Performance
Today, Lubrizol offers gear oil technology for customers developing products for the wind energy market: Lubrizol® 5088 is an additive package that can be combined with synthetic base fluids to formulate lubricants suitable for wind turbine applications. Lubrizol 5088, when combined with synthetic PAO, base fluid is designed to help extend wind turbine component life, by protecting gears in the harsh operating conditions sometimes found in wind turbine applications. In addition, products formulated with Lubrizol 5088 have excellent oxidation life which helps extend the life of the fluid, and are compatible with seals found in wind turbine gear boxes.
Sensor Technology: An Early Warning Keeps Small Problems Small
Community concerns about the “visual pollution” created by wind turbines are forcing businesses to set up their equipment in isolated areas. This makes monitoring and sampling oil in the gear boxes extremely difficult, but even more necessary. Monitoring oil identifies problems early and allows owners to avoid the expense of replacing gear boxes. Lubrizol’s FluiCheck™ diagnostic system represents a novel approach to diagnostics for wind energy hardware. Sensors measure and report on gear oil characteristics such as viscosity, moisture and metal particles. Sensors may also be useful in optimizing drain oil intervals, keeping maintenance costs low.
Ongoing Testing In The Real World
Lubrizol tests its chemistry in the lab under all types of conditions. However, lab tests can’t take the place of field-proven performance. In 2006, Lubrizol took advantage of a unique opportunity to test its products in the field. Cleveland’s Great Lakes Science Center (GLSC) installed a wind turbine to demonstrate wind power technology and create greater public awareness of this renewable energy source. Lubrizol supplied the lubricant for this single turbine as an in-kind donation to the Great Lakes Science Center. We also supplied a sensor monitoring system that measures and reports on gear oil characteristics such as viscosity, moisture, the presence of metal particles and the overall condition of the fluid.
In addition to its ongoing efforts at the GLSC, Lubrizol is also collaborating with Case Western Reserve University, located in the City of Cleveland (Cuyahoga County) and other local companies in the development of a wind energy research center. Case was awarded $3 million by the Ohio Department of Development to provide a platform for the development of wind power supply chain products. The project will establish a wind energy research center to integrate new wind turbine facilities at Case Western with research and development and industrial expertise for the commercialization of products and systems for the wind industry.
For more information on Gear Additives visit our website at www.lubrizol.com/IndustrialAdditives/IndustrialGear/.