Wind turbine gearboxes are expensive components prone to malfunction and when they break can result in costly production losses for any wind farm. Furthermore, they require frequent and extensive maintenance.
Wind Energy gearbox repair market has experienced steady expansion due to rising industrialization and urbanization worldwide, coupled with renewed global focus on renewable energy driving investments in wind turbines.
Wind Energy Gearbox Repairs
Wind turbine gearboxes must withstand immense loads in order to convert the rotational speed of rotor blades to generator shaft speed. Unfortunately, gusts and turbulence in wind can lead to uneven loading on gear components which causes misalignment between their teeth and eventual failure of this component.
Furthermore, the costs associated with hiring a crane large enough to replace the gearbox can have a devastating effect on a wind power plant’s operational profitability; just one gearbox replacement may cost as much as $250,000 (Kaiser & Frohlingsdorf 2010).
An active oil sampling program can identify and prevent issues that would otherwise lead to premature failure of gearboxes. For instance, using high-grade long-life lubricants such as Mobil SHC Gear 320 WT may help eliminate micropitting issues while decreasing maintenance requirements.
Wind Energy Gearbox Services
Wind turbine gearboxes are essential components, enabling generators to increase rotational speeds to generate power. Unfortunately, however, wind gusts and turbulence damage the gears gradually over time, leading to unplanned repairs or even complete failure, leading to lost productivity and reduced returns on financial investments.
Wind energy companies are experiencing an increasing need for maintenance services as older wind turbines undergo repowering to increase output. This trend will likely fuel an expansion in gearbox repair and refurbishment services over time.
SKF has designed kits for wind turbines that can reduce repair time and increase reliability, offering single-source supply of key parts that is readily available for rapid delivery. Furthermore, this solution offers an effective means of decreasing wind turbine downtime.
Wind Energy Gearbox Rebuild
Wind energy gearbox repair & refurbishment market is expanding rapidly as countries increase power production worldwide. Over the next several years, an estimated 32GW of geared turbines will require significant attention, including repairs or overhaul of gearboxes.
Refurbishment costs approximately one eighth of what it would take to buy new, according to Smits. A major operation to remove and install a 2MW gearbox could incur costs up to EUR90,000.
To reduce downtime, some companies keep replacement units on hand. ZF’s Services Powered by Analytics monitors equipment 24-7 and allows technicians to quickly respond to any issues, helping minimize outages while increasing availability and decreasing maintenance costs by preventing failures.
Wind Energy Gearbox Refurbishment
Wind turbine gearboxes convert low-speed rotations received from blades into higher speeds needed by generators for electricity production, typically lasting 20 years before needing refurbishment or replacement. Refurbishment typically is cheaper than replacing an entire gearbox and offers the same warranty and expected lifetime as purchasing a brand new unit.
The wind energy gearbox repair and refurbishment market is propelled by multiple factors, including increasing annual wind turbine installations and increased wind farm operator demand. North American growth will likely follow suit due to rising government investments in renewable energy technologies.
Local service and repair centers play a vital role in helping wind energy projects meet their success by decreasing plant downtime, cutting operational costs and increasing reliability. These services play a pivotal role.
Wind Energy Gearbox Overhaul
Wind power has grown increasingly important worldwide. Many nations are committed to producing renewable energy through wind turbines; however, to operate at maximum potential they require extensive maintenance services that include inspection and overhauls of gearboxes to reduce downtime, increase production levels and enhance reliability.
Wind turbines typically last 20 years under normal circumstances; however, gearboxes used to convert rotor blade rotational speed into generator-required speed can fail well before that deadline.
Logistics, cranes and manpower required to remove, transport, overhaul and reinstall a 2MW gearbox can be costly. To help reduce these expenses, SKF has developed service kits that can be quickly delivered. They help wind farm operators and utilities reduce downtime while increasing energy production by maintaining availability and maximising energy production.