Sentient Science recently applied its DigitalClone predictive modeling to REWITEC’s new nano and micro-particle-based lubricant additive DuraGear W100, and we’ve assessed that the treatment has a significant impact on life extension, which is unique because it can be applied while the wind turbine is operational.
REWITEC sought Sentient’s trusted third party evaluation, because Sentient had evaluated the life extension impacts that surface roughness has on bearings and gears in the aerospace and wind industries. REWITEC had already performed a variety of field tests to validate the treatment’s effect on bearings and gears, so the test case has an ideal technical fit.
Sentient developed a predictive model of a GE 1.5 wind turbine gearbox and studied the fatigue life impact of the W100 treatment on bearings and gears, including those that already had damage. Results indicated that the smoother gear surfaces would last significantly longer compared to untreated gearboxes. The intermediate pinion bearing and the planetary bearing showed life extension by a factor of up to 3.3X, and the intermediate pinion gear by up to 2.6X.
Sentient uses material science-based high performance computing to run thousands of trade off studies, taking into account the surface roughness and field representative operating conditions to determine life extension factors in a way that was cost effective and efficient. This allows Sentient to represent 20 to 30 years of field testing virtually across 100s of assets as if being tested on turbines in the field.
Operators looking to apply REWITEC’s DuraGear W100 surface treatment to their fleets could use DigitalClone to understand which turbines would benefit from the DuraGear W100 solutions. Offshore operators may be especially interested in seeing the benefits, because of the high maintenance costs and difficulty associated with uptower component and gearbox replacements. The surface treatment can be applied while the wind turbine is operational and uses the oil as a carrier to improve the life of bearings and gears, even those that are already in failure mode.
Next on the roadmap for REWITEC and Sentient is evaluating the REWITEC main bearing solution.
Join us for a Webinar on Wednesday, Sept. 7 at 8 a.m. or 2 p.m. EDT