Gearbox failure can halt wind turbine production, leading to loss of revenue and impacting operational profitability. Replacement costs typically reach half a million dollars or higher per replacement unit.
Moventas has introduced an innovative uptower repair process that could save operators thousands. Failed planetary stage gears and bearings of most GE 1.5MW wind turbines can now be repaired at a fraction of the price required to change out the entire gearbox.
Turbine Gearbox Repairs
Gearbox repairs are essential to the wind power industry, since failure can result in revenue loss and delays in energy production, not to mention higher maintenance costs for an entire turbine system.
Preventative maintenance can reduce these risks and improve wind turbine reliability. CloudVisit, for example, helps companies identify potential issues before they lead to costly repairs or downtime.
Though wind turbines were designed with 20 year design lifetime goals in mind, it is widely accepted that gearbox refurbishments may need to be performed twice or more in their lifespan due to exposure to extreme stress caused by wind turbulence. Replacing gearboxes may cost up to $1million and require several days of downtime for completion.
Turbine Gearbox Services
Wind turbine gearbox failure can be expensive to repair and cause costly downtime for operators, but preventive maintenance can reduce the risk of major failure, saving both time and money in repairs.
Utilizing high-performance gear oil such as Mobil SHC Gear 320 WT will allow you to reduce lubricant degradation and protect equipment against micropitting. By regularly sampling gearbox oil and using an IPLEX videoscope to inspect bearing roller surfaces, minor flaws can be identified before they worsen and cause significant damage.
Efficient condition monitoring detects changes to predefined condition indicators and allows you to accurately predict the remaining useful life of your gearbox using failure prediction models. Furthermore, such models can detect metallic wear debris and help identify sources of damage.
Turbine Gearbox Rebuild
The global wind turbine gearbox repair and refurbishment market is driven by increasing penetration of renewable energy into power mixes in each country, coupled with government initiatives to encourage renewables investment in this sector. Furthermore, annual turbine installations continue to rise while operators demand for repair service will fuel growth of this market over the projected period.
Preventive maintenance can help the wind-turbine industry combat high failure rates, with costly repairs and downtimes reduced to an acceptable level. CloudVisit’s Energy Software assists in early identification of gearbox issues so quick interventions can take place at workshops; thus reducing overall time spent in the field and increasing overall energy production.
Turbine Gearbox Refurbishment
Wind turbine gearboxes are massive components designed to withstand intense cyclic loads from their high-speed shaft connected to an electrical generator. While wind turbine gearboxes may be susceptible to failure, regular inspection can help protect against it; many companies have invested in refurbishing their equipment to minimize downtimes and enhance performance.
Wind turbine gearbox repair and refurbishment markets worldwide have seen rapid expansion due to increasing industrialization and urbanization worldwide. Each country is setting renewable energy targets that will drive investment into wind turbines over time.
Wind turbines typically require refurbishments at least twice during their 20-year lifetime. Many companies therefore opt for refurbishment solutions which offer similar warranties and expected lifetimes as purchasing a brand new gearbox.
Turbine Gearbox Overhaul
Wind turbine gearbox repair and refurbishment market growth has been driven by industrialization and urbanization worldwide, increasing demand for electricity and energy across the board as well as fueling growth of wind power industry via increased investment into it.
Modern wind turbines with traditional gear-drive technology require major gearbox overhauls several years post startup; this is particularly the case in offshore applications.
An overhaul on a large wind turbine can cost several million dollars, drastically undermining a project’s financial feasibility. Therefore, many lenders require customers to include an emergency provision in their project business plans in case extra materials break. A higher component scrap rate also raises project expenses significantly.