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Wind turbines and their components are exposed to high loads. The lubricants used are required to offer reliable performance
The constantly changing high loads, vibrations and varying over a long service life over a wide temperature range as well as
operating conditions require tough equipment. Add to those resist high load. For operators, these characteristics mean long
the external factors such as humidity and extreme temperature relubrication intervals for greases and long lubricant life for oils.
variations, and components will really suffer. Wind turbine main-
tenance is an arduous task and performed only at long intervals, What can you do to make your components and installations
which makes trouble-free operation even harder to accomplish. resist the extremely high stresses in a wind turbine?
Selecting the right lubricant is therefore paramount – for initial Speciality lubricants made by Klüber Lubrication are always
lubrication of a component as well as for relubrication during a good choice. As an expert in speciality lubricants, Klüber
operation. cooperates closely with the manufacturers of major components
and OEMs to push the limits of what can be technically achieved
After all, it is the lubricant that has to ensure reliable opera- even further: longer service intervals, longer component life and
tion of each machine element. Both fluids (oils) and consistent yet more reliable operation.
lubricants (greases) are used in wind power plants. The main
lubrication points are the main gearbox, the nacelle yaw gears, Have you ever considered how lubricants can influence your
the main and generator bearings, the blade pitch mechanism operating costs? The lubricant itself constitutes only a minor
and the yaw system. investment, but its effects can be tremendous.
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Higher performance – lower cost
A high-performance oil for enclosed Klübersynth GEM 4-320 N meets not only the requirements
stipulated by manufacturers of gears, rolling bearings and wind
gears operating under extreme loads turbines, but those of the operators as well.
As wind generators get ever larger, the power density in wind Besides an oil‘s viscosity, it is the additives that protect compo-
turbine gears is increasing, causing higher stress on the gears. nents reliably against micropitting and scuffing damage, hence
Experience has shown that the conventional gear oils available enabling longer gear life.
on the market today often fail to meet taxing requirements in
terms of wear protection for rolling bearings, micropitting resis- Micropitting is a form of wear occurring on highly loaded gears,
tance, foam and residue formation, and viscosity stability. especially in the contact area subject to mixed friction and
negative specific sliding. Material near the surface is plastically
deformed, and micro-cracks form. To the naked eye, the dam-
Why use a high-performance gear oil aged tooth flank area looks greyish. When sufficiently magnified,
minute spalling and pores become visible. The principal causes
from Klüber Lubrication? of micropitting are:
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Utilise the potential for savings Higher reliability
The following diagram shows the potential savings that can be High micropitting resistance helps prevent premature
attained by using high-performance gear oils. The costs arising fatigue damage
from the main gear of an average wind turbine over its entire
service life, taking into account oil costs, gear maintenance Highly loaded gears are susceptible to scuffing and micropitting.
and gear efficiency, are indicated: High pressure and temperature occurring in the mesh zone can
cause tooth damage and consequently lead to premature gear
Compared by costs: Mineral oil, PAO/ester oil failure. The risk of scuffing or micropitting damage is particularly
high with less-than-perfect tooth profiles and surfaces, or where
100 % shock loads, vibration, high surface pressures or high sliding
friction occur.
90 %
Micropitting changes the shape of the tooth flank, which may
80 %
affect the mesh dynamics and the gear‘s noise characteristics.
The cracks associated with micropitting may propagate, resul-
70 %
ting in actual gear pitting.
60 %
With its advanced additives, Klübersynth GEM 4-320 N has a
50 % high micropitting resistance of load stage ≥ LS 10 (GFT ”high“)
in the staged test according to FVA 54/7. In the associated endu-
40 % rance test, micropitting plateaus, showing that the product offers
high long-term micropitting protection.
30 % Klübersynth GEM 4-320 N exhibited this high degree of micropit-
ting resistance not only at 90 °C, but also at 60 °C, which is the
20 % usual inlet temperature in wind turbine gears
No requirement
No requirement
6
Standard Klübersynth Standard Klübersynth
CLP oil GEM 4-320 N CLP oil GEM 4-320 N
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Higher performance – lower cost
In field applications, micropitting formation is often reported even Protection against scuffing damage
though industrial gear oils with a high micropitting load capacity
are used. This is because such oils offer good micropitting resis- The FZG scuffing test according to ISO 14635-1 is generally
tance as examined in the load stage test. undertaken to test the capability of gear oils to protect against
scuffing damage. Load stage LS 12 of the FZG scuffing test
Klübersynth GEM 4-320 N with its modern additives has shown is the minimum requirement for CLP oils according to
to prevent propagation of this phenomenon through reaction at DIN 51517-3, and for EP oils according to AGMA 9005/E02.
the surface of the tooth flanks already affected by micropitting. Klüber Lubrication’s gear oils exceed this requirement by a large
margin, offering protection at significantly higher scuffing load
stages and speeds even under extreme shock load conditions.
A/8.3/90 A/16.6/90
14
Failure load stage LS
>14 >14
No requirement
12 ≥12
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Standard CLP oil Klübersynth GEM 4-320 N* Standard CLP oil Klübersynth GEM 4-320 N*
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Wear in slow motion
Viscosity is of primary importance when selecting gear oils, as it
The slow speed wear test C/0,05/60/12 according to significantly determines the formation of a lubricant film. Increas-
DGMK 377-01 determines the wear characteristics of oils ing viscosity results in thicker lubricant films, thus improving
under mixed and boundary friction conditions. the antiwear and damping properties as well as scuffing load
capacity. Viscosity decreases with increasing temperature and
The gear oils made by Klüber Lubrication pass the test run rises with increasing load. If the viscosity is too high, increased
with material loss due to wear of less than 40 mg and are churning and squeezing losses can result in excessive heat, es-
therefore classified under the “low” wear category. This is pecially at elevated peripheral speeds. If the viscosity is too low,
the best possible classification in DGMK 377-01. mixed friction conditions prevail and will result in increased wear.
200
150
Total wear (pinion + wheel)
100
50
40 mg
Viscosity [lglg]
0 (t)
20 40 60 80
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Higher performance – lower cost
What‘s good for gears needs to be good Compatibility with radial shaft elastomer seals
for rolling bearings
Many complaints regarding gears are raised because of oil
Gear damage is frequently associated with damaged rolling leakage. As conventional gear oils are frequently not sufficiently
bearings. This is why lubricant manufacturers are required to compatible with the seal elastomers, the sealing function can
prove that their products are not only suitable for the lubrication suffer and leakage occurs. High-performance lubricants from
of gears, but also for the bearings in the gearbox. Consequently, Klüber Lubrication were tested with excellent results in com-
the revised standard DIN 51517 part 3 contains the FE8 rolling bination with numerous materials under dynamic conditions in
bearing test developed by bearing manufacturer FAG. The FE8 specialised labs operated by the Freudenberg Group.
test serves to determine the wear characteristics of a gear oil
and forms the basis of estimating the effect a gear oil has on
rolling bearing life. In this test run, rolling element wear should
be less than 30 mg. Klübersynth GEM 4-320 N passes the FAG
FE8 test with very good results, confirming the optimum anti-
wear effect of this oil. Tests on Klübersynth GEM 4-320 N have
shown the wear rate is < 10 mg, i.e. by far below the permissible
maximum of < 30 mg. The standard‘s performance criteria are
therefore met without difficulty.
40
≤ 30
30
20
≤ 10
10
0
Standard CLP oil Klübersynth GEM 4-320 N
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Longer gear oil life
As high-performance gear oils from Klüber Lubrication have a
longer service life, OEMs can offer gear designs with reduced
maintenance requirements. Wind turbine operators have to KlüberComp Lube Technology
replace oils and filters less frequently, which results in lower KlüberComp Lube Technology is a holistic approach to
disposal costs. Operators demand gear oils with a long service the taxing requirements of today‘s power transmission
life. While engine oils in cars are normally changed after 15,000 technology. For you as a gear manufacturer or operator,
to 30,000 km, i.e. after 300 to 600 operating hours based on an KlüberComp Lube Technology can help to bring a substan-
average driving speed of 50 km/h, wind turbine oils are expected tial increase in gear performance.
to last for more than 25,000 hours. Standard lubricants specified
in various standards do not meet the requirements of the wind KlüberComp Lube Technology combines four important
energy sector today whereas, in contrast, gear oils from Klüber aspects
exceed them. Numerous tests show that our gear oils show a
low foaming tendency and can thus be fine-filtered. Components: focus on all gear components
Composition: lubricants formulated with high-quality
raw materials
Competence: direct consultation and service
Competitive: highest performance level
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Oil change: How it‘s done
When an oil change is performed, some residual oil will always They must not be mixed with gear lubricants having a different
remain in the gearbox. In many cases, these residues cannot be synthetic base oil. PAO gear oils from different manufacturers
tolerated and must be removed. The simplest method is to flush can be mixed, though. The content of other oils should be kept
the gearbox. If possible, the old oil is drained while still warm, i.e. as low as possible in order not to affect the properties of the
immediately after the gears have stopped. With a subsequent original gear oil.
flushing procedure, further residues are removed. The oil reser-
voir and inside gearbox walls can also be cleaned with a lint-free At operational oil temperatures over 80 °C, it is recommended
cloth - do not use cleaning wool - and a rubber blade. to use only seals made of fluorinated rubber or polytetrafluoro-
ethylene (PTFE). At temperatures below 80 °C, seals made from
A bigger problem is more profound contamination in the form of NBR are also resistant to PAO oils.
deposits caused by strongly aged oil. In such cases, cleaning oil
has to be used, and all accessible parts of the gearbox cleaned Epoxy and polyurethane paints are recommended for internal
manually. A suitable oil for cleaning gears is KlüberSummit Var- coating of housings.
nasolv, which quickly dissolves residues when added to mineral
oil or PAO. After draining approx. 10 % of the gear oil, the oil fill is
topped up with KlüberSummit Varnasolv. After 24 to 48 hours of
operation, the oil can be drained. Any remaining residues can be
removed mechanically.
The synthetic gear oil that was used for flushing must not be
used for lubrication afterwards, however, it can be kept for fur-
ther flushing operations. Prior to filling the fresh synthetic oil, oil
filters or filter elements should be replaced.
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Oil change checklist – Gear inspection
Drain oil while warm Drain approx. 10 % of the oil fill while warm
Inspect teeth
Top up with Varnasolv
Replace filters
Operate gears for 24 - 48 hours
Inspect teeth
Check oil level
Replace filters
Take reference oil sample, if required
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An innovative grease for all bearings
Lubrication of main, generator, blade rise in productivity. The operator‘s repair and spare parts costs
pitch and yaw bearings decrease, as does the cost for used grease disposal.
With Klüberplex BEM 41-141, the plant operator can restrict his
lubricant range to a single grease! This means that lubricant con-
To date, operators of wind power plants frequently have had to fusion can be eliminated, and storage and logistics are simplified.
obtain different types of grease to suit the varying speeds, loads,
sizes and functions of the individual bearings involved. Com-
monly wind parks contain units from different manufacturers and Why can Klüberplex BEM 41-141
different models, so various lubricant recommendations have to
be followed.
be used for all bearings?
This entails extra expenses for logistics, warehousing and grease
disposal, as well as a permanent risk of lubricant confusion. We have developed Klüberplex BEM 41-141 for the lubrication of
Since most turbines are relubricated manually, service techni- bearings in wind turbines, taking into account all critical condi-
cians have to carry all these different lubricants with them when tions under which the individual bearings operate. We attached
on maintenance visits. All required lubricants may also not be particular importance to the lubricant‘s performance during
always available at certain locations worldwide. standstill and swaying with brakes engaged. These are extremely
taxing operating conditions because friction is concentrated on
the same point over an extended period of time.
Innovation from Klüber Lubrication: In Klüberplex BEM 41-141, the consistency and base oil viscosity
were carefully tuned and combined with efficient oil release to
a single grease for all wind turbine enable reliable build-up of a protective lubricant film and excel-
bearings lent grease distribution.
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Results obtained in SNR-FEB 2 rolling bearing grease test
Competitor product 1: wear limits
The antiwear behaviour of lubricating greases in rolling bearings were exceeded so test had to be
subject to small oscillating rolling and sliding motion is deter- stopped after 13.5 hours.
mined on the SNR FEB 2 rolling bearing grease tester. Since
the wear pattern in this test resembles the indentation caused
in the Brinell hardness test, the SNR FEB 2 test is also referred
to as ”false Brinell test“. An axial load of 8000 N is applied,
corresponding to a Hertzian pressure of 2100 N/mm2, with a
frequency of 24 Hz and over an angle of oscillation of ± 3°. The
test duration is 5 and 50 hours for a test temperature of the lower
shaft washer of –20 °C and ambient temperature, respectively.
Competitor product 2: wear limits
were exceeded so test had to be
Klüberplex BEM 41-141 was tested at ambient temperature, stopped after 39.6 hours.
resulting in less than 5 mg of wear, and at –0 °C, resulting in
less than 20 mg – both excellent values!
Comparative tests of other lubricants available on the market
showed that they fail to attain similarly good values even at
ambient temperature.
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An innovative grease for all bearings
Low-temperature characteristics
of greases
In operation, wind power plants are often subject to huge tem- This test showed that both Klüberplex BEM 41-132 and
perature variations. The very low temperatures are especially Klüberplex BEM 41-141 retain their excellent lubricity at very low
tough for the operation of wind turbines. Electric components, temperatures. It also demonstrates their outstanding antiwear
plastic and other parts are not designed for temperatures below characteristics. At this temperature, a bearing wear of less than
−10 or −15 °C, so turbines without a cold climate package are 20 mg was attained with both lubricants – an excellent result.
normally switched off if temperatures drop below these values.
Still, the rolling bearing grease has to resist changing under A special exposure test has shown that both greases
such temperatures, even while the turbine is standing still. As Klüberplex BEM 41-132 and Klüberplex BEM 41-141 meet the
soon as the outside temperatures rise to acceptable levels, the temperature requirements of the wind energy sector without
wind power plant restarts. Starting at cold temperatures is often difficulties - even if they are considerably lower than the grease‘s
facilitated by a heating system. At the time of start-up, the rolling nominal lower service temperature. Even at temperature far
bearing grease still has to provide its full performance. To make below zero, the lubricant does not change. And no changes
sure the grease is capable of doing so, it has to undergo numer- means it offers full performance when the turbine is started
ous tests prior to approval. again.
The lower service temperature of a grease is normally deter- Furthermore, Klüberplex BEM 41-132 and Klüberplex BEM 41-141
mined by means of the standardised flow pressure test or the offer very god adhesion even at extremely low temperatures,
low-temperature torque test (IP 186). Upper service temperatures which also contributes to good lubrication in the cold. Klüber
are ascertained on the FE9 rolling bearing tester (DIN 51821) or in has confirmed adhesion at low temperatures in an especially
the SKF-ROF test. For Klüberplex BEM 41-141, the low-tempera- developed bent-strip test - conducted at temperature conditions
ture torque test resulted in a lower service temperature of considerably below the lower service temperature range.
−40 °C, and the SKF-ROF test in an upper service temperature
of 150 °C.
14
Hints for practice
15
Clean solution for the yaw
and pitch bearing gear
The main problem with the open teeth of the slewing ring and The corrosion degree ≤ 2 proves a good anticorrosive effect.
the blade pitch adjustment is that the lubricant can drop off. This
leads to insufficient lubrication and eventually higher wear. In
addition, the black lubricants that have been used so far cause Load-carrying capacity
stains on the nacelle and the tower.
In the FZG test, Klüberplex AG 11-461/462 and Klübersynth AG 14-61
Klüber offers Klüberplex AG 11-461/462 (NLGI classes 1 and 2) attain load stage 12, which means that all three products fully
and Klübersynth AG 14-61, white lubricants for the teeth of the meet the requirements for a gear grease.
slewing ring and the blade pitch bearings. They retain their good
lubricity and remain highly adhesive even at temperatures of
-40 °C, so they protect the gear teeth reliably against wear. Low-temperature behaviour
The lubricants’ good adhesion leads also to lower grease con-
sumption and longer maintenance intervals. Klüberplex AG 11-461/462 can be pumped using normal spray-
ing systems without heating at temperatures down to approx.
0 °C, and Klübersynth AG 14-61 down to –30 °C. Tests in
Klüberplex AG 11-461/462 Klüber’s own test bay have shown that all three products offer
better adhesion than traditional black greases at −40 °C as well
and Klübersynth AG 14-61 testing as at high temperatures. In tests performed on a vertical surface
at 70 °C, none of the three products dropped from the surface
Resistance to salt water even after 48 hours.
60
50
40
30
20
10
0
-10
-20
-30
-40
-50
-60 Klübersynth AG 14-61 Klüberplex AG 11-461/462
16
Hints for practice
17
Optimally equipped with
our speciality lubricants
Main bearing
Klüberplex BEM 41-141
Gear motor
Klübersynth GEM 4 N series
Klübersynth GH 6 series
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Slip ring
Klüberalfa YM 3-30 Spray
Yaw bearing
Klüberplex BEM 41-141
Yaw bearing drive
Klüberplex AG 11-461/462
Klübersynth AG 14-61
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Lubricants for enclosed gears
Component Requirements
20
Speciality lubricant Comment Benefits
Klübersynth GEM 4-320 N – Synthetic high-performance gear oil for – High FZG scuffing resistance > 14 offers protection
Klübersynth GH 6-320 particularly low and elevated temperatures at normal and elevated loads.
and high loads
– Oil life approx. 5 x longer than that of – High micro-pitting resistance, both at 90 °C and 60 °C,
mineral oil based lubricants protects against premature fatigue failure.
21
Lubricants for bearings
Component Requirements
Main bearing – Low speeds
– Occasional oscillating motion
– High loads
– Vibration
22
Speciality lubricant Comment Benefits
– Less downtime, more production time
23
Lubricants for slew ring drives and slip rings
Component Requirements
Slew ring drive – Low motion amplitude
(yaw and pitch control) – High load
– Vertical tooth flanks
– Tendency towards corrosion
Component Requirements
Slip rings – Wear and corrosion increase transition resistance
24
Speciality lubricant Benefits
Klüberplex AG 11-461 – The product offers good adhesion and does not drop from the tooth flanks, even in the vertical
Klüberplex AG 11-462 orientation (unlike other lubricants). This reduces lubricant consumption, disposal and nacelle
Klübersynth AG 14-61 cleaning costs.
– Good pumpability and metering in centralised lubricating systems, hence trouble-free turbine operation-
and availability.
– Anti-corrosive effect provided during non-operation as well as in offshore applications where the nacelle
is exposed to salty, humid air.
– Klüberplex AG 11-461/462 can be used for large and small open gears.
Lubricant Benefits
Klüberalfa YM 3-30 Spray – Longer contact life and equipment availability as Klüberalfa YM 3-30 protects the contact against harmful
influences.
– Klüber YM 3-30 Spray is a slip-ring oil with long-term resistance and a particular low base oil viscosity.
Spray application is particularly even, simple and clean, making for low-maintenance operation.
25
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Publisher and Copyright:
Klüber Lubrication München SE & Co. KG
27
www.klueber.com