Details
| Original language | English |
|---|---|
| Article number | 205760 |
| Number of pages | 12 |
| Journal | WEAR |
| Early online date | 3 Feb 2025 |
| Publication status | E-pub ahead of print - 3 Feb 2025 |
Abstract
Modern geared wind turbines rely on the adequate performance of their lubricant to ensure optimum operation of their main gearboxes. Potential oil ageing mechanisms, such as oxidation or additive depletion, can degrade oil performance over time. An oil that performs satisfactorily throughout the entire life of the turbine can reduce the downtime, resources, and costs associated with oil changes or repairs. Therefore, the purpose of this study is to investigate the ageing of field oil through oil analysis and artificial ageing. In addition, the possibility of oil service life extension by top-treating used oils with additives was investigated. For the field oil evaluation, oil samples were taken from operating wind turbines with lifespans up to 16 years. The deterioration of their copper corrosion, foaming, and wear performance was assessed using standard tests and its influence on gearbox operation was identified. Although these properties had degraded to some extent, most oils continued to perform satisfactorily. To counteract oil ageing, top-treating (adding additives to the field oils) was performed to restore the corresponding properties of oils. Subsequent standard tests confirmed that this approach is generally effective, but there are still some potential problems. To further investigate the oils’ lifespan limits, field oils were subjected to artificial ageing. This process involved oil heating and the artificial, accelerated consumption of anti-wear additives. Experimental results indicated that artificial ageing has only a minor influence on wear despite a significant reduction in additive concentration. In conclusion, proper monitoring of oils and timely top-treat have the potential to achieve lifelong wind turbine gearbox lubrication.
Keywords
- Additive consumption, Lifetime lubrication, Oil ageing, Oil analysis, Oil top-treat, Wind turbine gearbox
ASJC Scopus subject areas
- Physics and Astronomy(all)
- Condensed Matter Physics
- Engineering(all)
- Mechanics of Materials
- Physics and Astronomy(all)
- Surfaces and Interfaces
- Materials Science(all)
- Surfaces, Coatings and Films
- Materials Science(all)
- Materials Chemistry
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In: WEAR, 03.02.2025.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Towards lifetime lubrication of wind turbine gearboxes
T2 - Technical and physical investigations on used oils
AU - Liu, Muyuan
AU - Bayer, Gernot
AU - Reimers, Merle
AU - Schünemann, Wilhelm
AU - König, Florian
AU - Jacobs, Georg
AU - Schelenz, Ralf
AU - Bader, Norbert
AU - Poll, Gerhard
AU - Marian, Max
N1 - Publisher Copyright: © 2025 The Authors
PY - 2025/2/3
Y1 - 2025/2/3
N2 - Modern geared wind turbines rely on the adequate performance of their lubricant to ensure optimum operation of their main gearboxes. Potential oil ageing mechanisms, such as oxidation or additive depletion, can degrade oil performance over time. An oil that performs satisfactorily throughout the entire life of the turbine can reduce the downtime, resources, and costs associated with oil changes or repairs. Therefore, the purpose of this study is to investigate the ageing of field oil through oil analysis and artificial ageing. In addition, the possibility of oil service life extension by top-treating used oils with additives was investigated. For the field oil evaluation, oil samples were taken from operating wind turbines with lifespans up to 16 years. The deterioration of their copper corrosion, foaming, and wear performance was assessed using standard tests and its influence on gearbox operation was identified. Although these properties had degraded to some extent, most oils continued to perform satisfactorily. To counteract oil ageing, top-treating (adding additives to the field oils) was performed to restore the corresponding properties of oils. Subsequent standard tests confirmed that this approach is generally effective, but there are still some potential problems. To further investigate the oils’ lifespan limits, field oils were subjected to artificial ageing. This process involved oil heating and the artificial, accelerated consumption of anti-wear additives. Experimental results indicated that artificial ageing has only a minor influence on wear despite a significant reduction in additive concentration. In conclusion, proper monitoring of oils and timely top-treat have the potential to achieve lifelong wind turbine gearbox lubrication.
AB - Modern geared wind turbines rely on the adequate performance of their lubricant to ensure optimum operation of their main gearboxes. Potential oil ageing mechanisms, such as oxidation or additive depletion, can degrade oil performance over time. An oil that performs satisfactorily throughout the entire life of the turbine can reduce the downtime, resources, and costs associated with oil changes or repairs. Therefore, the purpose of this study is to investigate the ageing of field oil through oil analysis and artificial ageing. In addition, the possibility of oil service life extension by top-treating used oils with additives was investigated. For the field oil evaluation, oil samples were taken from operating wind turbines with lifespans up to 16 years. The deterioration of their copper corrosion, foaming, and wear performance was assessed using standard tests and its influence on gearbox operation was identified. Although these properties had degraded to some extent, most oils continued to perform satisfactorily. To counteract oil ageing, top-treating (adding additives to the field oils) was performed to restore the corresponding properties of oils. Subsequent standard tests confirmed that this approach is generally effective, but there are still some potential problems. To further investigate the oils’ lifespan limits, field oils were subjected to artificial ageing. This process involved oil heating and the artificial, accelerated consumption of anti-wear additives. Experimental results indicated that artificial ageing has only a minor influence on wear despite a significant reduction in additive concentration. In conclusion, proper monitoring of oils and timely top-treat have the potential to achieve lifelong wind turbine gearbox lubrication.
KW - Additive consumption
KW - Lifetime lubrication
KW - Oil ageing
KW - Oil analysis
KW - Oil top-treat
KW - Wind turbine gearbox
UR - http://www.scopus.com/inward/record.url?scp=85217261748&partnerID=8YFLogxK
U2 - 10.1016/j.wear.2025.205760
DO - 10.1016/j.wear.2025.205760
M3 - Article
AN - SCOPUS:85217261748
JO - WEAR
JF - WEAR
SN - 0043-1648
M1 - 205760
ER -