Molyduval Lubricants for Wind turbines

Molyduval Lubricants for Wind turbines

Long Life lubrication

Lubrication of wind turbines is crucial for maintaining their performance, reliability, and long effectivity. Here are the primary reasons and the associated problems if lubrication is inadequate or improper:

Why Lubrication is Necessary?

Reduce Friction and Wear

• The moving parts in a wind turbine, such as the gearbox, bearings, and pitch and yaw systems, experience significant friction. Lubrication reduces this friction, minimizing wear and tear.

Heat Dissipation

• Friction generates heat, which can damage components and reduce efficiency. Lubricants help dissipate this heat, maintaining optimal operating temperatures.

Corrosion Protection

• Wind turbines operate in harsh environments, often exposed to moisture and varying temperatures. Lubricants provide a protective barrier against corrosion and oxidation.

Load Distribution

• Proper lubrication helps in distributing loads evenly across bearing surfaces, reducing the risk of premature failures.

Contaminant Removal

•  Lubricants can help in flushing out contaminants such as dirt and metal particles, which can cause abrasion and damage to components.

Lubrication with highest quality oils and greases would extend the life of the equipment, increase the period between maintenance and thus increase the revenue.

Problems Due to Inadequate or Improper Lubrication

Increased Wear and Tear

•  Without adequate lubrication, friction increases, leading to accelerated wear and potential failure of critical components like gears and bearings.

Overheating

• Lack of proper lubrication can lead to excessive heat generation, causing thermal expansion and potential deformation of parts. Overheating can also degrade the lubricant itself, further exacerbating the problem.

Corrosion and Rust

• Insufficient lubrication leaves metal surfaces exposed to the elements, increasing the risk of rust and corrosion, which can weaken structural integrity.

Operational Downtime

• Failures due to improper lubrication can lead to significant downtime for repairs or replacements, impacting the turbine's energy production and profitability.

Noise and Vibration

• Poor lubrication can cause increased noise and vibration, indicating excessive wear and potential misalignment of parts, which can lead to further damage if not addressed.

Contaminant Accumulation

• Without proper lubrication, contaminants can accumulate in the system, causing abrasion and further wear of components, leading to more frequent maintenance needs and potential failures.

Types of Lubricants Used in Wind Turbines

The main lubrication points  are the main gearbox, the nacelle yaw gears, the main and generator bearings, the blade pitch mechanism and the yaw system.

Synthetic Oils

Molyduval Tantalus A 320 – Synthetic PAO based oil. Often used for their superior performance in extreme temperatures and better longevity compared to mineral-based oils.
Using Tantalus A 320 instead of mineral oils in wind turbines offers several advantages that align with the operational demands and environmental considerations of modern wind energy systems. Here are the key reasons:
1. Superior Lubrication Performance

• Temperature Stability:  Molyduval Tantalus A … type Synthetic oils maintain their viscosity and lubrication properties over a wider temperature range, which is critical for wind turbines operating in diverse and often harsh environmental conditions.
• Oxidation Resistance: They resist oxidation and thermal breakdown better than mineral oils, leading to longer oil life and more consistent performance.

2. Enhanced Wear Protection:

• Improved Additives:  Molyduval Tantalus A 320  often contain advanced additives that provide better protection against wear, corrosion, and deposits. This helps in prolonging the life of critical components such as gearboxes and bearings.

3. Extended Service Intervals:

•  Longer Oil Life: Due to their chemical stability and resistance to breakdown, synthetic oils typically require fewer changes, reducing maintenance frequency and costs.

4. Energy Efficiency:

• Reduced Friction:  Molyduval Tantalus A 320  can reduce friction more effectively than mineral oils, leading to lower energy losses and improved overall efficiency of the turbine.

5. Environmental Benefits:

•  Biodegradability:  Molyduval Tantalus A 320  are formulated to be more environmentally friendly, with lower toxicity and better biodegradability compared to conventional mineral oils.
• Lower Carbon Footprint: The production and disposal of synthetic oils can be more environmentally sustainable, contributing to the overall goal of reducing the carbon footprint of wind energy operations.

6. Extreme Condition Performance:

• Cold Weather Performance: Molyduval Tantalus A … oils flow better at low temperatures, ensuring that lubrication is effective even in cold climates.
• Heat Resistance: They also perform better at high temperatures, which is crucial for turbines in hot climates or those that operate continuously under heavy loads.

7. Compatibility and Stability:

• Material Compatibility: Molyduval Tantalus A 320   less likely to cause damage to seals, gaskets, and other components, reducing the risk of leaks and failures.
• Hydrolytic Stability:  Molyduval Tantalus A 320  more resistant to hydrolysis (breakdown in the presence of water), which is important in the moist, outdoor environments where wind turbines operate.

Synthetic Greases

Lubrication with Molyduval Pegasus LKA 1 P- many parts, generator, blade pitch and yaw system bearings of wind turbines. Molyduval Pegasus LKA 1 P - Used in rolling and plain bearings and other parts where a more viscous lubricant is required to stay in place and provide longer-lasting protection.
Using Molyduval Pegasus LKA 1 P in wind turbines provides several key benefits that align with the demanding operational requirements and environmental considerations of wind energy systems. Here are the main reasons for preferring Molyduval Pegasus LKA 1 P synthetic grease:

1.    Enhanced Lubrication Properties:

• Wide Temperature Range: Molyduval Pegasus LKA 1 P maintains its lubricating properties across a broad temperature spectrum, which is essential for wind turbines exposed to varying and extreme weather conditions.
• Stable Viscosity: It offers consistent viscosity and performance, ensuring reliable lubrication under different load and speed conditions.

2.    Improved Wear Protection:

• Superior Additives: Molyduval Pegasus LKA 1 P often include advanced additives that provide better protection against wear, corrosion, and oxidation, which helps in extending the lifespan of bearings.
• Film Strength: They form a stronger lubricating film, reducing metal-to-metal contact and minimizing wear.

3.    Extended Service Intervals

• Longer Grease Life: Due to their chemical stability and resistance to breakdown, Molyduval Pegasus LKA….  type synthetic greases typically require less frequent re-lubrication, reducing maintenance efforts and costs.
• Reduced Downtime: Less frequent maintenance means wind turbines can operate for longer periods without interruption, enhancing overall productivity.

4.    Environmental Resistance:

• Water Resistance: Molyduval Pegasus LKA 1 P is more resistant to water washout and can maintain their performance even in wet conditions, which is crucial for wind turbines exposed to rain, snow, and humidity.
• Oxidation Stability: They are less prone to oxidize and degrade, which is important for components that are difficult to access and maintain.

5.    Extreme Load Handling:

• High Load Capacity: Molyduval Pegasus LKA 1 P can handle higher loads and stresses, which is important for the heavy-duty bearings in wind turbines that support significant mechanical loads.
• Shock Load Protection: They offer better protection against shock loads, reducing the risk of sudden failures in critical bearing applications.

6.    Energy Efficiency:

• Low Friction: Molyduval Pegasus LKA 1 P reduce friction more effectively, leading to lower energy losses and improved efficiency of the wind turbine.
• Molyduval Pegasus LKA 1 P provides superior lubrication, protection, and performance in wind turbine bearings compared to conventional mineral-based greases. These benefits lead to increased reliability, reduced maintenance, and enhanced overall efficiency of wind turbines, making synthetic grease the preferred choice for this critical application.

Lubrication of open teeth slewing rings and blade pitch in wind turbines

Molyduval Prometheus AKM 1 Z and AKM 2 Z – solution for lubrication of open teeth slewing rings and blade pitch in wind turbines. The main problem with open teeth slewing rings and blade pitch in wind turbines is their susceptibility to wear and environmental contamination. The open design exposes the teeth to harsh weather conditions, dirt, and debris, leading to accelerated wear, corrosion, and potential failures. This can compromise the precision and reliability of blade pitch control, which is critical for optimizing the turbine's performance and ensuring its safe operation. Molyduval Polypan LKA 1 or Molyduval Pegasus LKA 1 P or for open gears Prometheus AKM 1Z or 2Z. 

Lubrication of Main Shaft Bearings in wind turbines

Use high-quality synthetic greases – Molyduval Pegasus LKA 1 P or Molyduval Nora LA 1 HV  main shaft bearings. Use sensors to monitor the temperature and vibration of the main shaft bearings. Abnormal readings can indicate lubrication issues or the need for maintenance.

Lubrication of Gearbox

Use high-quality synthetic oils – Molyduval Tantalus A 320 or Syntholube G 320 EP viscosity shold be changed. Flushing oil MOLYDUVAL Tantalus YE 200

Yaw Bearings system bearings

For yaw system bearings in wind turbines, recommended to use Molyduval Pegasus LKA 1 P or Rabilub CEN 1 HV high-quality, heavy-duty synthetic and biodegradable  greases. For open gear lubrication Prometheus AKM 1 Z or AKM 2 Z. Key characteristics of the ideal lubricant include:
1.    High Load-Carrying Capacity: To withstand the significant stresses and loads experienced by yaw bearings.
2.    Excellent Water Resistance: To protect against corrosion and maintain lubrication properties in harsh environmental conditions.
3.    Wide Temperature Range: To ensure reliable performance in varying temperatures typical in wind turbine operation.
4.    Anti-Wear and Anti-Corrosion Additives: To extend the lifespan of the bearings and reduce maintenance needs.
5.    Good Adhesion Properties: To stay in place and provide continuous lubrication even under movement and vibration.
6.    Long Service intervals: Very good protection and long maintenance intervals. 

Synthetic greases designed specifically for wind turbine applications are typically the best choice for yaw system bearings.

Generator Bearings lubrication

For generator bearings in wind turbines, it is recommended to use Molyduval Polypan LKA 2 or Molyduval Pegasus LKA 1 P or Molyduval Polypan LKA 1, a high-quality synthetic greases:
1. High Load-Carrying Capacity: To handle the stresses and loads on generator bearings.
2. Wide Temperature Range: To ensure effective lubrication in the varying temperatures experienced within the generator.
3. Excellent Oxidation Stability: To resist degradation over time and extend the lubricant's service life.
4. Good Water and Corrosion Resistance: To protect against moisture and potential corrosion.
5. Anti-Wear Additives: To minimize wear and extend the life of the bearings.
6. Low Friction: To reduce energy losses and improve efficiency.
7. Long Service intervals: Very good protection and long maintenance intervals. 

A synthetic grease or oil specifically formulated for high-speed and high-temperature applications is typically the best choice for many devices and parts in wind turbines.