At present, the main units of wind turbines in operation in China have gradually entered a period of frequent faults, and the proportion of mechanical failures related to lubrication is quite high. Lubrication is very important for the reliable operation of wind power equipment. Shell industrial lubricating oil experts said in an interview with China Electric Power News that it is recommended that wind turbine equipment maintenance personnel choose gear lubricating oil with good comprehensive performance. This type of lubricating oil not only effectively protects the main gearbox, Extending the lifespan of the main gearbox can also ensure production efficiency and reduce downtime.
In fact, this viewpoint has been supported by some research institutions. According to MAKE's prediction, based on the trend of a two-year warranty before 2010 and a 3-5 year warranty thereafter in China, 47 gigawatts of wind power installed capacity should have fulfilled the warranty contract by the end of 2014. However, due to various factors, it is expected that only 55% of the warranty capacity will be successfully issued. With the introduction of more policies in the next 3-5 years, the technology and quality of wind turbines will continue to improve, and the quality assurance procedures will become increasingly standardized. By the end of 2020, the proportion of successful quality assurance capacity will significantly increase to 94%.
According to various statistics at home and abroad, the shutdown of wind turbines caused by damage to gearboxes and bearings accounts for approximately 40% to 60% of all faults. Among them, lubrication failures caused by improper selection of lubricating oil account for a high proportion. Therefore, strengthening the research and selection of high-performance lubricating oils, paying attention to the maintenance and upkeep of equipment lubrication systems, is particularly important for the normal operation of high-power fans.
It is understood that the parts of the fan that need lubrication mainly include the main gearbox, yaw and pitch gearbox, hydraulic control system, open gear, yaw pitch bearing, main bearing and generator bearing, among which the most critical part is the main gearbox. As the core of the fan transmission system, it plays an extremely important role in the entire system operation. Once the main gearbox malfunctions, replacing or overhauling it will bring great losses.
Based on the unit power generation cost of a 1.5 megawatt wind turbine, the annual operating and maintenance costs account for approximately 18%. As the lubrication system is an important component for the normal operation of wind turbines, its selection and maintenance directly affect the normal operation and power generation cost of wind turbines.
According to Shell Industrial Lubricant experts, after analyzing the statistical data of wind turbine failures in Sweden, Finland, and Germany, it was found that the gearbox is not the most frequently malfunctioning component in the entire wind turbine, but it is the component that causes the longest downtime. Mechanical failures account for about half of the total failures, while the proportion of mechanical failures related to lubrication is 35%, 29%, and 25%, respectively.
During the 12th Five Year Plan period, China's wind power industry continued to develop, reaching 200 million to 250 million kilowatts in 2020. Wind power owners are concerned about the productivity of wind turbines, while operation and maintenance personnel are concerned about the reliability of wind power systems. Efficient and reasonable lubrication management is one of the basic measures to ensure the long-term normal operation of wind turbines. Improving lubrication management level can alert equipment faults, reduce unplanned downtime, improve operation and maintenance efficiency, extend equipment life, reduce costs, and be beneficial for energy conservation and environmental protection.
The key to maintaining the continuous increase in electricity production is to maintain the smooth operation of the fan, in which lubricating oil plays a crucial role. As one of the larger energy companies, Shell provides product initial installation services for nearly 40% of wind turbines in China, and tailors comprehensive wind power services according to the needs of post market owners. It solves the inconvenience and safety problems caused by remote and high-altitude oil changes for customers, helps wind power equipment manufacturers and operators further strengthen equipment maintenance and management, thereby ensuring the safe and efficient operation of wind power equipment.
For wind farms, unplanned downtime and maintenance caused by malfunctions are undoubtedly the natural enemies of project revenue. The Shell Industrial Lubricant Expert Team collaborates extensively with industry clients to conduct in-depth research on improving fan efficiency and reducing maintenance costs, providing various lubrication solutions tailored to actual situations, and providing more diverse choices for fan maintenance personnel. For areas with concentrated wind farms, Shell's professional service provider system provides timely and efficient wind power services for wind farms, including wind turbine oil change engineering vehicles, fast oil testing, technical demonstrations, and lubrication related training.
Experts suggest that by strengthening the lubrication management and status monitoring of the entire wind turbine generator set, the wear and replacement of spare parts can be reduced, the reliability of device operation can be improved, and ultimately the profitability of the wind turbine generator set can be improved.
Fan gearbox failures are closely related to manufacturing processes, installation, and maintenance, but gear failures caused by adhesion, pitting, corrosion, and abrasive wear account for approximately 80% of the total gear failure rate. However, due to the remote location and involvement of high-altitude operations of wind turbines, it is very difficult to dismantle and repair the main parts on site. Therefore, ensuring the reliable and stable long-term operation of wind turbines is more important than other industries. Therefore, maintenance personnel for wind turbine equipment should correctly select, add, maintain, monitor, and manage wind power oil products, and effectively prevent potential risks.