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The Global Wind Energy Council is forecasting 1,221GW of new renewable electricity capacity to be built worldwide over the next seven years, and the wind turbine sector is expected to continue experiencing momentous year-on-year growth from $24 billion today to $44.6 billion by 2032.

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The lubrication system within a wind turbine gearbox is critical in ensuring smooth operation and long-term durability. It is the lifeblood of the gearbox, and its role cannot be overstated, especially in the face of evolving wind turbine designs and operating conditions.

This phenomenon has been named White Etching Cracking, or WEC, and although researchers agree that its exact cause remains unclear, many suggest that lubricants may play a significant role. Interestingly, the description of WEC is nearly identical to the description of hydrogen wear.

The task of effectively lubricating a wind turbine gearbox is challenging, fraught with difficulties arising from harsh operating conditions, stringent performance requirements, and high expectations for longevity and reliability. This article will explore these circumstances, why gearboxes in wind turbines are failing prematurely and how modern synthetic lubricants can be the solution.

Mechanical wear in large wind turbines is a serious issue with investigations finding gearbox failures within five years of operation, writes Leyla Alieva, CEO and co-founder of NEOL Copper Technologies.

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From what research has discovered so far, studies are concentrated on the amount of energy required to remove hydrogen ions from either water or from the base oil. The sheer size of turbines, along with the amount of torque that goes through their gearboxes, and the power that flows through their blades, results in a sizeable but destructive amount of energy.

Taking hydrogen wear into consideration, another of the most significant challenges for wind turbine gearboxes is elemental. The inconsistent and unpredictable nature of wind speed and direction has a major impact. These variations can result in fluctuating loads and torque on the gearbox, increasing wear and tear on the components. The lubricant must effectively protect the gearbox components under these dynamic operating conditions.

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If all wind turbine operators were to embrace and adopt high-efficiency synthetic lubricants, it would represent a significant step forward in self-sufficiency, engineering and component maintenance. This new technology can ensure that landfills do not become dumping grounds for cracked wind turbine gearboxes. Instead, these expensive components can be preserved to last for their intended use and help the world produce more reliable renewable energy.

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Take offshore and coastal wind turbines as a prime example of where the weather and the natural environment can severely impact the durability of a gearbox. In these conditions, moisture and salt can penetrate the gearbox, leading to corrosion of components. As a wind turbine needs to be robust to stay operational, so does its gearbox. This sort of environment means a gearbox requires lubricants with excellent water separation capabilities and corrosion inhibitors to protect it.

There is a pressing need for more advanced lubrication solutions that can cater to the evolving demands of wind turbines. While the world is becoming more reliant on wind turbines, it is imperative to keep this source of renewable energy reliable and cost effective. High-efficiency synthetic lubricants can be the answer, especially as they are designed in a way that can protect gearboxes from the devastating WEC phenomenon that has plagued wind turbines.

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Research is ongoing to determine what causes such a high failure rate in wind turbine gearboxes. A key factor, that affects every instance when two surfaces meet and move against each other, is hydrogen wear. The science of this can be traced back to the 1960s, when Russian engineer Professor Dmitry N. Garkunov made two discoveries while investigating mechanical failure in aircraft landing gears.

Given the fact that many wind turbine gearboxes are not achieving their expected 20-year design life, and around 60% of the industry’s gearbox failures are caused by WEC, it is unsurprising that wind turbine operators and OEMs are conducting extensive investigations on how to solve this complex problem.

Consequently, cracks appear on the inner ring of high-speed shafts (HSS) and high-speed intermediate shafts (HSIS) bearings. If left ignored, these cracks will spread and damage the ring, shafts, gears, and gearbox housing, leading to catastrophic premature failures.

Whilst wind has been used as a natural form of energy to power machines to grind grain and pump water since the 9th century, the invention and installation of the first electricity-generating wind turbines only dates back to the 1880s.

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Wind turbines often operate in locations subject to extreme hot and cold temperatures. High temperatures can reduce lubricant viscosity (and therefore load-carrying), while extremely low temperatures can cause the lubricant to thicken, leading to inadequate lubrication. Therefore, the lubricant must have a broad operating temperature range to maintain its viscosity and performance under any temperature or adverse conditions.

When examining this cracking up close, researchers concluded that three factors appear to be working together: non-metallic inclusions, sliding, and hydrogen. However, as the cracks occur below the surface, it is impossible to detect with the naked eye, and by the time it reaches the surface the damage is done.

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Sadly, some of the traditional lubricants cannot meet these performance demands, leading to decreased efficiency, increased maintenance, and in some cases, high-cost premature failure. However, newer, high-efficiency synthetic lubricants could be the answer as they are designed with long-term component maintenance in mind.

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Wind power has rapidly evolved throughout the 20th century, becoming an essential form of renewable energy and now plays a crucial role as a climate change adaptation strategy.

Unfortunately, mechanical wear in large multi-megawatt (MW) wind turbines has become an increasingly serious issue over the last decade. In-depth investigations have found widespread gearbox failures within five years of operation, meaning operators now consider them to be the single most expensive wind turbine component to replace.

High-efficiency lubricants can reduce the stress on bearings, ensuring an adequate lubrication film, thereby reducing metal-to-metal contact that may lead to WEC. Moreover, the introduction of certain performance additives into the lubricants that eliminate the hydrogen wear will protect against specific conditions leading to WEC.

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Lubrication is critical to ensuring a wind turbine gearbox remains operational. As wind turbine technology has evolved, leading to larger, more powerful turbines operating in increasingly challenging conditions, the demands on gearbox lubrication have also grown.

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Finding a way to preserve gearboxes is imperative to keeping them operational and cost effective. After all, these gearboxes have been designed with a life expectancy of 20 years, but the harsh reality is that they are not lasting for a quarter of that time.

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Garkunov discovered that during friction, copper ions were being selectively transferred into the crystalline grid of iron forming a thin film. Then, he found that hydrogen was the primary cause of metal surface deterioration. Further research has found that hydrogen wear occurs during sliding and rolling contacts that are found in rotating machinery such as gears and hydraulics.

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