Wind turbine gearbox

condition assessment

Monitoring the condition of wind turbine gearboxes A twin approach

is essential to guarantee machine integrity for their On-site inspection using a video endoscope is the most
whole designed lifetime. Under the IEC 61400-4:2012 effective way to assess actual gearbox condition, providing
standard, a wind turbine gearbox is considered to be an acute vision of the current state of all the accessible
a non fail-safe component whose failure may in turn components.
lead to failure of other major parts of the turbine.
For this reason, and since they operate under severe Alongside and complementary to this, remote analysis of
mechanical stress conditions, gearboxes need regular wind turbine data provides crucial additional information
thorough attention. Fully equipped to provide onsite to aid in the full evaluation of gearbox condition.
inspection and remote wind turbine monitoring,
ENGIE Laborelec is your ideal partner for gearbox
condition assessment, wherever you are in the world.
Benefits of onsite inspection
Component degradation can be detected
at an early stage.
Warranty claims and end-of-warranty
punch lists can be easily established.
Maintenance, investment and strategy
can be optimized.
Expensive wind turbine repairs and
unplanned downtime are minimized.

Benefits of remote services

The condition of inaccessible components
can be monitored.
Historical overview and evolutions trending
can be analyzed.
Real time and historical operating conditions
can be recorded.
Endoscopic inspections are guided more
End of warranty: thorough visual inspection is precisely, giving better results.
the final opportunity to detect latent defects
Additional information on global wind turbine
At the end of the warranty period, a thorough
operating condition can be collected.
endoscopic inspection is highly recommended to
detect latent defects that could impact the lifetime No downtime, no significant impact on
of the machine. Relying on oil analysis or simple day-to-day operation.
monitoring of SCADA data, such as temperature
or vibration levels, is insufficient.
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In practice
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Frequently asked questions

Onsite inspection Remote analysis Why should gearboxes be inspected?

1. Walk down: exterior, Relevant operational Some components could need replacement during the
gear stay, lubrication data are monitored gearbox life time, depending on the design parameters.
and cooling system. and analyzed: Harsh conditions, improper operation and poor
maintenance can greatly reduce sub-component lifetime,
2. Inspection for debris CMS but timely detection of component degradation can help
at collectors, magnets extend gearbox life and avoid costly unplanned repairs,
SCADA
and oil filters. as well as injury to personnel and catastrophic failures.
Oil analysis
3. Endoscopic
inspection Service reports
When is a gearbox inspection advised?
Gearbox inspection is recommended in five situations.
More in-depth lab investigations, such
as oil analysis or examination of materials, On delivery or commissioning, since degradation
are available to clarify specific questions, could originate from improper manufacturing,
for example in the framework of root transport, storage or handling.
cause analysis.
At the end of the warranty period, since monitoring
vibration data alone is insufficient for clear warranty
Bearing degradation detected claims.
just in time by visual inspection
When indicated by predictive services or
maintenance planning, preferably driven by
turbine operating conditions and loading.
When damage is detected, through CMS
or SCADA alarms.
Where forensic data are required in the context
of a root cause failure analysis.

Can a gearbox be fully inspected?

No. Some gearbox components are not accessible for
inspection. Since inspecting each bearing roller and the
complete circumference of the bearing rings would be
This severe bearing degradation was detected during a visual time consuming and inefficient, endoscopic inspections
inspection. Immediate gearbox replacement was necessary
can provide no more than a statistical overview of
due to induced degradation of neighbouring components.
Such degradation, if undetected, could have led to abrupt the component condition. Complementary services
seizure, with potential dramatic consequences including such as CMS, SCADA and oil analysis are therefore
shaft rupture or gearbox total loss. recommended.

Would you like Five reasons for you to choose Laborelec

to know more? • Wide-ranging technical expertise in electricity generation,
grids, and end-use
ENGIE Laborelec • Customers enjoy enhanced profitability and sustainability
Stephane Bronckers of energy processes and assets
[email protected] • Unique combination of contract research and operational assistance
+32 2 382 03 54 • Independent advice based on certified laboratory and field
analysis worldwide
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