Wind turbines employ gearboxes to convert the low rotation speeds of blades into the higher speeds required to generate electricity, yet these critical components frequently fail before reaching their expected 20-year lifespans, creating safety risks, expensive repairs and downtime.
CloudVisit Energy Software allows inspection teams to identify potential issues early and address them before they become costly, thus reducing unscheduled maintenance and downtime of equipment, saving both money and downtime for operators.
Wind Turbine Gearbox Repairs
Wind Turbine Gearbox Repairs are essential in maintaining this vital part of a wind turbine, without which it may fail far earlier than anticipated. CloudVisit Energy Software can reduce repair frequency and minimize downtime for maximum turbine uptime.
Due to global urbanization and industrialization, the global wind turbine gearbox repair and refurbishment market is experiencing unprecedented expansion. Europe holds a sizable share, while Asia-Pacific is projected to grow quickly over time. North America should experience gradual expansion due to increasing investments in renewable energy technologies like wind power.
Current companies that perform wind turbine gearbox repairs and refurbishments fall into four distinct categories. Small workshops specialize in repairs; medium-sized independent companies like Danish marine gearbox specialist Mekanord offer fuller refurbishments; while major manufacturers typically possess extensive facilities. COVID-19 caused shortages in raw materials and labor supply in the industry; forcing many businesses to implement innovative strategies in order to adapt their business models in response.
Wind Turbine Gearbox Services
Within the lifetime of a wind turbine, its gearbox will likely require replacement after 20 years of service. A failure at this point is a serious concern and can erode profitability significantly.
Wind gusts and turbulence contribute to this problem by creating uneven bearing loads in a gearbox, leading to misalignment of gear teeth and increased wear rates – not an issue for small machines, but larger machines may experience decreased availability as a result of this condition.
Replacement costs for a 2MW gearbox typically total around EUR 160,000, including both its purchase price and all related logistics, crane rental, and manpower costs associated with removal/installation. This expense represents one of the primary obstacles limiting market growth.
Wind Turbine Gearbox Rebuild
Wind turbine gearboxes convert the slow rotations of blades into the high speeds necessary for producing electricity, yet sometimes fail to meet their expected 20-year lifespan due to cracking rolling-element bearings in their gearboxes.
Regular gearbox inspection and maintenance can help prevent these failures from occurring, with inadequate lubrication or neglect leading to minor problems escalating into costly damages.
Repair and refurbishment of wind turbine gearboxes is an extremely profitable business for large independent companies such as ME Productions, Dana Industrial, Stork (a Fluor company), and ZF Friedrichshafen. A standard refurbishment for 2MW gearboxes costs roughly EUR160,000-190,000. When considering logistics and crane costs associated with removal/installation costs this pricetag increases further.
Wind Turbine Gearbox Refurbishment
Wind turbine maintenance can be a complex business. A team of professionals must travel to remote locations, haul equipment over 300 feet in the air and work in confined spaces. Faulty components or equipment could negatively impact performance of the whole machine leading to costly repairs.
Wind turbine gearbox failure rates average 5.5 incidents every 10 machine-years and result in over one day of downtime, according to research published by World Journal Control Science and Engineering 2013.
Gearbox repair markets are growing, particularly in Asia Pacific countries due to an increasing emphasis on renewable energy sources. Larger independent companies are entering wind turbine repair and refurbishment businesses as competitors to original equipment manufacturers (OEM).
Wind Turbine Gearbox Overhaul
Wind turbine gearboxes are integral parts of providing reliable energy generation; however, they can be vulnerable to a number of failures and require regular maintenance for optimal functioning. A damaged gearbox may lead to significant downtime and costly repairs that necessitate immediate attention.
Wind energy has seen rapid global adoption due to rising electricity demands and government initiatives to promote renewable sources in order to lower carbon footprints, creating an opportunity for the global wind turbine repair and overhaul industry.
Pall’s latest report provides an in-depth examination of market size and growth opportunities for various types of wind turbine gearboxes.