Development of Wind Turbine Gear Oil – Servomesh WEG 320
Wind Energy Sector in India
India’s wind energy sector is led by indigenous wind power industry and has shown consistent progress. The expansion of the wind industry has resulted in a strong ecosystem, project operation capabilities and manufacturing base of about 10,000 MW per annum. The country currently has the fourth-highest wind installed capacity in the world with total installed capacity of 39.25 GW (as on 31st March 2021) and has generated around 60.149 Billion Units during 2020-21.
Wind Mill Lubrication
Wind turbine lubrication exists at the very extremes of industrial gear applications in terms of temperature, load weights, bearing wear, maintenance, accessibility and basic lubricant performance. Most of the wind turbine gearbox manufacturers have compiled or are in the process of compiling new lubrication specifications. These specifications are more stringent than those for industrial gear applications, and more accurately reflect true operating conditions, including low-temperature conditions. The structure of the windmill is as under:
The gearbox is situated just where the winds are the strongest - as high as 300 feet. A special gearbox oil filter, separate from the normal oil cooling system, ensures high oil cleanliness. This is a key factor in desert or arid conditions where airborne dust can get into gearboxes, act as an abrasive, and eventually lead to (three-body) contact fatigue failures. The FAG FE 8 bearing test, which is part of the standard DIN 51517 Part III specification, is required by all gearbox manufacturers. Nonetheless, oil drain intervals have rested between 8 and 12 months. The expectations for new generation oils for offshore applications could be a drain interval of up to three years.
The ultimate gearbox oil for wind turbine application should have the thermal stability of a top-tier hydraulic oil combined with the EP properties of current gear oils. In addition, the components added to prevent micro-pitting need to be carefully selected to ensure that surface activity is balanced. Additionally, turbine gear oil specifications are beginning to reflect demand for higher lubricant performance through testing for enhanced oxidation and corrosion resistance, and improved bearing and long-term operational performance.
The Ultimate Solution
With continuous focus on innovation while exploring, creating, and delivering value to the customer under Make In India campaign, SERVOMESH WEG 320 was developed meeting DIN 51517 Part III specification with OEM requirements of FAG FE8. The product (Servomesh WEG 320) is tailor-made for the wind turbine gear oils for catering this niche segment. The product not only meets viscosity temperature behaviour & oil service life standards but also has excellent resistance to foaming. The product is designed for excellent filterability & demul- sibility characteristics.
Starting with ‘zero’ penetration and success in the wind energy segment, the product was offered to Inox Wind, India’s leading wind energy solutions provider servicing IPPs, Utilities, PSUs, Corporates and Retail Investors. While instilling the belief that an Indian Company can actually supply a competitive and ‘value for money’ formulation, negotiations were carried out. The customer saw the potential and capability in Indian Oil and placed the first ever purchase order for direct supplies of both initial fill and maintenance business with SERVOMESH WEG 320 without any trial.
Today, IOC stands with 100% business for wind turbine gear oil with M/s Inox Wind. It is pertinent to note that the development of wind turbine gear oil by IOC is the first such offering by an Indian company. Wind energy is a niche market segment, the successful supply and post supply seamless operational efficiency by IOC has been a great breakthrough in this segment.
