Customer Success Story
Thanks to Optimally Lubricated Shaft Bearings
Dongfang Electric Corporation (DEC) was looking for a total solution package for the main shaft bearings of its wind turbines in Fujian Xinghua Bay. The requirement was to guarantee the availability of the wind turbines for more than 25 years, despite harsh conditions, and crucially to avoid failures. Schaeffler supplied the appropriate bearing and optimum lubrication solution.
Benefits
The solution impressed with
Increased grease service life and bearing life: Especially for special designs of the main shaft bearing also with bolt cage
Customized lubricant: perfectly designed for high loads, low start temperature and large temperature ranges
High water and corrosion resistance, especially suitable for high humidity and salty environments
Challenge
Solution
First, the Schaeffler experts carried out calculations using the BEARINX tool to determine the appropriate bearing arrangement and optimum grease. The overall solution comprised a customized main shaft bearing that was specially equipped with a bolt cage and, for optimum lubrication, the program recommended the use of performance grease Arcanol LOAD460.In addition to providing other information, the BEARINX calculation report and rig test also showed that the viscosity and additive package of LOAD460 ideally meet the requirements for heavy-duty operation.
The Arcanol LOAD460 specifications show outstanding corrosion protection properties, as demonstrated by the Emcor test, in addition to a first-rate starting behavior at extremely low temperatures (-40 °C) and excellent wear protection properties. For the customer specifically, this means an increased grease service life, even at high loads and across a wide temperature range, resulting in optimized maintenance intervals and a reduced grease consumption for the system.
What’s special
DEC is highly satisfied with the overall solution. After Arcanol LOAD460 was successfully used in the 10 MW wind power plant for the main shaft of the turbine, the global corporation plans to use Arcanol LOAD460 in further wind power plants. Schaeffler also offers perfectly matched bearing and lubrication solutions for applications in rolling mills, the steel industry, the cement industry, construction machinery, and the paper industry.
Technical Details
Technical information on the 10 MW Wind Turbine
Place, installation | Fujian Xinghua Bay, 2020 |
| Capacity for generating electric energy | 10MW |
| Bearing type | 2-TRB |
| Filling volume (grease) | 96.91KG 77.55KG |
| Relubrication Interval | 6 months |
Savings
Damage to offshore wind turbines and the resulting outlay associated with dismounting bearings and replacing components can incur huge costs.
The rental costs of boats, cranes and other equipment for the replacement of a main shaft bearing alone are around 800,000 Euro. An unplanned downtime takes an avarage of 20 days. By losing 2.2 million kilowatt hours, costs arise in the amount of 200,000 Euro.
